COTO Full Document - Oct 2020

South Africa
COTO
Committee of Transport
Officials
Standard Specifications for Road

and Bridge Works for South
African Road Authorities
Draft Standard (DS )

CHAPTER 1: GENERAL
October 2020
P er mis si on is gr a nt e d t o fre el y c op y, print a nd di stri but e

this Draft Standard document for industry use.
SUMMARY OF ALL CHAPTERS AND SECTIONS
CHAPTER 1: GENERAL
1.1 GENERAL PREAMBLE
1.2 GENERAL REQUIREMENTS AND PROVISIONS
1.3 CONTRACTOR’S SITE ESTABLISHMENT AND GENERAL OBLIGATIONS
1.4 FACILITIES FOR THE ENGINEER
1.5 ACCOMMODATION OF TRAFFIC
1.6 CLEARING AND GRUBBING
1.7 LOADING AND HAULING
CHAPTER 2: SERVICES
2.1 GENERAL REQUIREMENTS AND TRENCHING FOR SERVICES
2.2 DRY SERVICES
2.3 WET SERVICES
2.4 ENERGY AND OTHER SERVICES
CHAPTER 3: DRAINAGE
3.1 DRAINS
3.2 CULVERTS
3.3 CONCRETE KERBING AND CHANNELING, ASPHALT BERMS, CHUTES, DOWNPIPES, CONCRETE, STONE PITCHED AND
GABION LININGS FOR OPEN DRAINS
CHAPTER 4: EARTHWORKS AND PAVEMENT LAYERS: MATERIALS
4.1 BORROW MATERIALS
4.2 CUT MATERIALS
4.3 EXISTING ROAD MATERIALS
4.4 COMMERCIAL MATERIALS
4.5 ALTERNATIVE MATERIALS
CHAPTER 5: EARTHWORKS AND PAVEMENT LAYERS: CONSTRUCTION
5.1 ROADBED
5.2 FILL
5.3 ROAD PAVEMENT LAYERS
5.4 STABILISATION
5.5 RECONSTRUCTION OF PAVEMENT LAYERS
CHAPTER 6: CONCRETE LAYERS
6.1 PAVER LAID CONCRETE LAYERS
6.2 SEGMENTAL BLOCK PAVING LAYERS
CHAPTER 7: MAINTENANCE AND REPAIR OF CONCRETE LAYERS
7.1 REPLACEMENT OF EXISTING JOINT SEALANT
7.2 REPAIR TO CONCRETE PANELS AND CONCRETE ADJACENT TO UNCONTROLLED CRACKS AND EXISTING JOINTS
7.3 REMOVAL AND REINSTATEMENT OF EXISTING CONCRETE LAYERS
7.4 REINSTATEMENT OF SLAB SUPPORT BY GROUT INJECTION
7.5 REINSTATEMENT OF RIDING QUALITY
7.6 REINSTATEMENT OF SURFACE TEXTURE
CHAPTER 8: PRETREATMENT AND REPAIR OF EXISTING LAYERS
8.1 PRIME COAT
8.2 COVER SPRAYS, FOG SPRAYS AND REJUVENATION SPRAYS
8.3 TEXTURE TREATMENT
8.4 RUT AND/OR DEPRESSION CORRECTION
8.5 STANDARD CRACK SEALING
8.6 GEOSYNTHETIC CRACK SEALING
8.7 PLANING
8.8 PATCHING AND EDGE BREAK REPAIR
8.9 REPAIR OF SURFACE DEFECTS
CHAPTER 9: ASPHALT LAYERS
9.1 ASPHALT LAYERS
CHAPTER 10: SURFACE TREATMENTS
10.1 GENERAL REQUIREMENTS FOR SURFACE TREATMENTS
CHAPTER 11: ANCILLARY ROAD WORKS
11.1 PITCHING, STONEWORK, CAST IN SITU CONCRETE FOR PROTECTION AGAINST EROSION
11.2 NON-STRUCTURAL GABIONS
11.3 GUIDE BLOCKS AND KILOMETRE MARKERS
11.4 ROAD RESTRAINT SYSTEMS
11.5 FENCING
11.6 ROAD SIGNS
11.7 ROAD MARKINGS AND ROAD STUDS
11.8 LANDSCAPING AND PLANTING PLANTS
11.9 FINISHING THE ROAD AND ROAD RESERVE AND TREATING OLD ROADS
CHAPTER 12: GEOTECHNICAL APPLICATIONS
12.1 PILING
12.2 GROUND ANCHORS
12.3 GROUND IMPROVEMENT
12.4 LATERAL SUPPORT
12.5 SHOTCRETE
12.6 MECHANICALLY STABILISED EARTHWALLS
12.7 PIPE JACKING, HORIZONTAL DIRECTIONAL DRILLING, RAMBORING AND MICRO-TUNNELLING
12.8 GROUND DRAINAGE
12.9 SLOPE PROTECTION MEASURES
12.10 HARD EXCAVATION BY BLASTING
12.11 GEOSYNTHETICS
12.12 CONSTRUCTION DEWATERING
CHAPTER 13: STRUCTURES
13.1 FOUNDATIONS
13.2 FALSEWORK, FORMWORK AND CONCRETE FINISH
13.3 STEEL REINFORCEMENT
13.4 CONCRETE
13.5 PRESTRESSING
13.6 BEARINGS
13.7 JOINTS
13.8 ANCILLARY STRUCTURAL ELEMENTS
13.9 STRUCTURAL STEELWORK FOR MINOR STRUCTURES
13.10 PAINTING OF MINOR STRUCTURES
13.11 STRUCTURAL STEELWORK FOR MAJOR STRUCTURES
13.12 STRUCTURAL STEEL PROTECTIVE TREATMENT OF MAJOR STRUCTURES
13.13 INCREMENTAL LAUNCHING OF BRIDGE DECKS
13.14 SPECIALIST STRUCTURES
CHAPTER 14: REPAIR AND REHABILITATION OF STRUCTURES
14.1 ACCESS FOR BRIDGE REHABILITAION
14.2 CORROSION SURVEY METHODS AND TESTING OF NEAR SURFACE CONCRETE PROPERTIES
14.3 DEMOLITION AND REMOVAL OF STRUCTURAL CONCRETE AND STEELWORK
14.4 SURFACE AND STRUCTURAL REPAIR OF CONCRETE MEMBERS
14.5 ANCHORING OF REINFORCEMENT, GROUTING AND CRACK INJECTION
14.6 SPRAYED CONCRETE FOR STRUCTURES
14.7 PROTECTIVE COATINGS AND TREATMENTS FOR CONCRETE
14.8 EXTERNAL BONDING OF STEEL AND CARBON FIBRE
14.9 REPAIR AND REPLACEMENT OF ANCILLARY STRUCTURAL ELEMENTS
14.10 JACKING OF BRIDGE STRUCTURES
14.11 REPAIR OF STEEL ELEMENTS
CHAPTER 15 – reserved for future use

CHAPTER 20: QUALITY ASSURANCE

20.1 TESTING MATERIALS AND JUDGEMENT OF WORKMANSHIP
FOREWORD
Compiled under the auspices of the:

Committee of Transport Officials (COTO)
Roads Coordinating Body (RCB)
Road Materials Committee (RMC) – a subcommittee of RCB
Published by:
The South African National Roads Agency SOC Limited
PO Box 415, Pretoria, 0001
Disclaimer of liability:
The document with its Chapters is provided as a Draft Standard (DS) without any warranty of any kind, expressed or implied.
No warranty or representation is made, either expressed or implied, with respect to fitness of use and no responsibility will be
accepted by the Committee or the authors for any losses, damages or claims of any kind, including, without limitation, direct,
indirect, special, incidental, consequential or any other loss or damages that may arise from the use of the document.
All rights reserved:

No part of this Draft Standard document may be modified or amended without permission and approval of the Committee of
Transport Officials (COTO). Permission is granted to freely copy, print and distribute this Draft Standard document for use by
industry.
Existing publication:
The new COTO Standard Specifications for Road and Bridge Works for South African Road Authorities was approved by
COTO on 18 August 2020 as a Draft Standard (DS) and will be replacing the COLTO Standard Specifications for Road and
Bridge Works for State Road Authorities (1998 Edition).
Existing contracts and tenders in the design phases based on the COLTO Standard Specifications (1998 Edition) will remain
unaffected but will be phased out during the next 6 months and the COTO Standard Specifications (2020 Edition) will be
mandatory for use in procurement documents advertised as from 1 March 2021.
Document versions:
Draft Standard (DS). The Draft Standard will be implemented in industry for a period of two (2) years, during which written
comments may be submitted to the COTO subcommittee. Draft Standards (DS) have full legal standing.
Final Standard (FS). After the two-year period, comments received are reviewed and where appropriate, incorporated by the
COTO subcommittee. The document is converted to a Final Standard (FS) and submitted by the Roads Coordinating Body (RCB)
to COTO for approval as a final standard. This Final Standard is implemented in industry for a period of five (5) years, after which
it may again be reviewed. Final Standards (FS) have full legal standing.
Comments:
Comments on the Draft Standard Chapters should be provided in writing on the Excel spreadsheet provided on the websites
mentioned below and e-mailed to cotorevision@nra.co.za .
Please note:
This document and its various Chapters will only be available in electronic format.
The Draft Standard (DS) Chapters will be made available for download on the South African National Roads Agency SOC Ltd
(SANRAL) and Department of Transport websites.
August 2020 version replaced with October 2020 version due to amendments to Chapters.
TABLE OF CONTENTS
CHAPTER 1: GENERAL ................................................................................................................................................ 1-1
1.1 GENERAL PREAMBLE ........................................................................................................................................... 1-1
PART A: SPECIFICATIONS...............................................................................................................................................................................................1-1
PART B: LABOUR ENHANCEMENT .................................................................................................................................................................................1-3
PART C: MEASUREMENT AND PAYMENT .....................................................................................................................................................................1-4
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES.......................................................................................................................................1-7
1.2 GENERAL REQUIREMENTS AND PROVISIONS .................................................................................................. 1-8

1.3 CONTRACTOR’S SITE ESTABLISHMENT AND GENERAL OBLIGATIONS ...................................................... 1-30

1.4 FACILITIES FOR THE ENGINEER ......................................................................................................................... 1-36

1.5 ACCOMMODATION OF TRAFFIC .......................................................................................................................... 1-50

1.6 CLEARING AND GRUBBING.................................................................................................................................. 1-70

1.7 LOADING AND HAULING ....................................................................................................................................... 1-80

CHAPTER 1: GENERAL
1.1 GENERAL PREAMBLE
CONTENTS
PART A: SPECIFICATIONS
A1.1.1 SCOPE
A1.1.2 DEFINITIONS
PART B: LABOUR ENHANCEMENT

PART C: MEASUREMENT AND PAYMENT
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES
A1.1 GENERAL PREAMBLE

A1.1.1 SCOPE
The scope of each Section is given in Part A of each Section of every Chapter of this Standard Specification. Each Part A and Part B of each
Section of every Chapter generally contain the following standard headings:
• Scope
• Definitions
• General
• Design by Contractor / Performance based systems
• Materials
• Construction equipment
• Execution of the works
• Workmanship
Part A of this Section A1.1 only contains definitions that are generic and which are relevant or applicable to the other Sections and Chapters of
this Standard Specification.
The intention is that this Standard Specification should be compatible with the applicable Conditions of Contract. However, due to differences in
the terminology and terms of the different standard contract conditions, there are instances were there may be conflict between the Conditions
of Contract and the requirements given in this Standard Specification. In such instances the terminology and provisions given in the Conditions
of Contract will prevail.
A1.1.2 DEFINITIONS
Definitions of various items are given in Part A of each Section of every Chapter of this Standard Specification where they are most applicable.
Where relevant these definitions shall apply throughout this Standard Specification.
The definitions for the various contractual terms are given in the Conditions of Contract but as various contract conditions may be used the
terminology used and the definitions of the terms may differ. The terms below are therefore defined for the purposes of interpreting this
Standard Specification. In the event of any discrepancy, the terms given in the applicable Conditions of Contract shall be used. The meaning of
any other contractual terms not defined below shall be as given in the applicable Conditions of Contract.
The meaning of any other words and phrases used in this Standard Specification shall be interpreted in accordance with the applicable
definitions and/or descriptions given in the unabridged version of the Oxford English Dictionary.
Conditions of Contract - addresses the risks, liabilities and obligations of the contracting parties and the agreed procedures for the
administration of the contract. The latest edition, or the applicable edition as defined in the Contract Documentation, of one of the following three
standard conditions of contract, which have been recommended by the South African Construction Industry Development Board (CIDB) for road
and bridge Works, shall apply as specified in the Contract Documentation:
• Conditions of Contract for Construction for Building and Engineering Works designed by the Employer as published by the International
Federation of Consulting Engineers (FIDIC Red Book).
• General Conditions of Contract for Construction Works as published by the South African Institution of Civil Engineering (GCC).
• NEC Engineering and Construction Contract Documentation as published in the United Kingdom.
Contract - is a binding legal agreement between the Employer and the Contractor in terms of which the Works as defined in the Contract
Documentation shall be carried out.
DRAFT STANDARD (DS) OCTOBER 2020 1-1

Contract Documentation - includes all the documents which define the content and terms of the Contract entered into by the Employer and the
Contractor. The Contract Documentation usually consists of the following documents:
• Conditions of Contract.
• Contract Agreement.
• Drawings.
• Letter or Form of Tender.
• Letter or Form of Acceptance.
• Pricing Schedule.
• Project Specifications.
• Scope of the Works.
• Special (or Particular) Conditions of Contract.
• Standard Specification (this document) and
• any other documents forming part of the contract.
Contractor - is the person or firm named as the Contractor in the Contract Documentation and who is responsible for the construction of the
Works in accordance with the applicable Contract Documentation.
Dayworks - are used to determine payment for work which cannot be quantified in specific units in the Pricing Schedule, or for additional work
ordered by the Engineer during the construction period which was not foreseen at tender stage and for which no applicable rates exist in the
Pricing Schedule.
Defects Notification Period - also referred to as the defects liability period or the maintenance period, or the defect correction period, is the
period allowed for the discovery and notification of any defects in the Works that must be rectified by the Contractor as specified in the Contract
Documentation.
Drawings - are the drawings of the Works included in the Contract Documentation and any additional or modified drawings signed and issued
by (or on behalf of) the Employer in accordance with the Contract.
Employer - is the person, entity or firm named as the Employer in the Contract Documentation for whom the Works are to be carried out and
who is responsible for the payment and acceptance of the Works.
Engineer - is the person, entity or firm appointed by the Employer, or another person who may be delegated to assist the Engineer in terms of
the applicable Conditions of Contract, to manage aspects of the Contract and to supervise the construction of the Works in accordance with the
applicable Contract Documentation. Depending on the applicable Conditions of Contract “Engineer” should be read as follows: FIDIC –
Engineer GCC – Employer’s Agent NEC – Project Manager or Supervisor
Guideline documents - are technical documents which contain specifications related to certain aspects of road construction. These documents
may be included, or referred to, in the Contract Documentation, either as additional specifications to be adhered to if so specified in the Contract
Documentation or as additional guidelines to best construction practice for the benefit of the Contractor should he choose to follow them.
Pricing Schedule - contains the payment items required for the Works, together with the estimated quantities and the agreed rates for each
payment item. The Pricing Schedule is also sometimes referred to as the bill of quantities or the schedule of quantities.
Project Specifications - contain the additional project specific requirements applicable to the construction of the Works to the required quality
and standard for a particular contract.
Road reserve - the entire area, as demarcated, proclaimed or due to be proclaimed, which is reserved for a road.
Site / Site of the Works - shall mean the entire road reserve, inclusive of road junctions and property accesses, required for construction of the
Works as defined by the limits of construction given in the Contract Documentation. It shall also include areas within statutory building lines
where work has to be carried out and any additional lengths of road required for the placement of advanced warning road signs and/or traffic
accommodation measures beyond the limits of construction as shown on the drawings. Where the following places are provided by the
Employer the Site shall also include areas outside of the road reserve required for construction camps, site offices, laboratories and housing,
borrow areas, spoil areas and stockpile areas. The exact extent of the limits of the construction will be verified once the Site is handed over to
the Contractor.
Site Agent / Contractor’s Representative / Construction Manager - the person appointed by the Contractor to act on behalf of the Contractor
on the site of the Works.
Special Conditions of Contract - (sometimes referred to as the Particular Conditions of Contract) are additional Conditions of Contract which
apply specifically to a particular contract.
Standard Specification - contains the standard requirements applicable to the construction of the road and bridge Works to the required quality
and standard.
Taking-over Certificate - is issued to indicate completion of the Works as defined in the relevant Conditions of Contract that are applicable to
the particular contract. Depending on the applicable Conditions of Contract “Taking-over Certificate” should be read as follows: FIDIC – Taking-
over Certificate GCC – Certificate of Completion NEC – Take over
Performance Certificate - this certificate is issued to indicate the end of the Defects Notification Period and it is also sometimes referred to the
final approval certificate as defined in the relevant Conditions of Contract that are applicable to the particular contract.
Works - means all the temporary and permanent work required to be done as defined in the Contract Documentation.
Word gender interpretation - except where the context requires otherwise, words indicating one gender include both genders.

B1.1 GENERAL PREAMBLE
CONTENTS
B1.1.1 SCOPE
B1.1.2 DEFINITIONS
B1.1.3 GENERAL
B1.1.4 DESIGN BY CONTRACTOR / PERFORMANCE BASED SYSTEMS
B1.1.5 MATERIALS
B1.1.6 CONSTRUCTION EQUIPMENT
B1.1.7 EXECUTION OF THE WORKS

B1.1.8 WORKMANSHIP
B1.1.1 SCOPE
The scope of any labour enhancement and the methods and specifications related to labour enhanced construction are contained in Part B of
each of the relevant Sections of this Standard Specification. The requirement for the use of labour enhanced construction methods to satisfy any
particular project goals will be set out in the Contract Documentation.
The specifications given in Part A of this Standard Specification will apply to all work carried out using labour enhanced construction methods
unless some of the specifications in Part A are replaced with revised specifications in Part B that are specifically applicable to the specified
labour enhanced construction methods.
B1.1.2 DEFINITIONS
Labour Enhancement – Labour enhancement is the process of improving the scope for the use of manual labour as an alternative to using
machines to increase employment opportunities on a project.
Labour Intensive – Labour intensive operations are those operations which, by their basic nature, require a significant amount of manual labour
and to a large extent exclude the use of machines.
Project Labour Goals – Project labour goals are the requirements specified for a project to enhance the use of labour in the normal
construction operations and/or to use additional labour intensive methods to replace or augment traditional construction methods that usually
involve lower levels of manual labour.
B1.1.3 GENERAL
Any activity specified in Part A, where hand work is given as an alternative, shall be executed in such a way as to maximise labour.
Clauses B1.1.4 to B1.1.8 are not applicable to this Section.

C1.1 GENERAL PREAMBLE
CONTENTS
C1.1.1 PREAMBLE
C1.1.2 MEASUREMENT
C1.1.3 PAYMENT
C1.1.4 VARIATION FROM SPECIFIED NOMINAL RATES OF APPLICATION OR FROM NOMINAL MIX PROPORTIONS
C1.1.1 PREAMBLE
The general measurement and payment conditions which are applicable to all the Chapters of this Standard Specification as well as elsewhere
in the Contract Documentation, unless specified differently, are given below.
The measurement and payment of the various items required for the Works is described in the payment items which are given in Part C of each
separate Section contained in the different Chapters of this Standard Specification. Each Part C of each separate Section contains a list of items
that are not measured separately as well as a list of items that are measured and paid for using items specified in other Sections or Chapters.
If additional payment items are required for a particular contract they will be specified in the Contract Documentation for that contract.
The following terms relating to payment shall be applicable as specified in the Conditions of Contract and shall have the meanings given below:
• Lump sum - a fixed sum tendered by the Contractor which covers all his costs, incidentals, overheads and profit for providing materials
and supervising and carrying out the work and/or services that are specified under the relevant pay item.
• Prime cost sum - a sum to cover the actual cost of the supply of materials and/or work that will be provided by a supplier and/or
subcontractor that will be nominated by the Employer or a sum to cover the costs of items and/or services provided by an outside
provider where the cost is not known in advance.
• Provisional sum - a sum to cover the actual cost of materials and/or work that cannot be clearly defined before the Contract was
awarded. The Contractor will usually be asked to obtain several quotations for the materials and/or work required and submit them to
the Engineer who will approve one of the quotations and instruct the Contractor to appoint the selected service provider or
subcontractor. Alternatively, the Contractor may be asked to submit a price for providing the materials and carrying the work out himself
for approval by the Engineer.
If alternative meanings are given in the Conditions of Contract those meanings will apply instead of the meanings given above.
C1.1.2 MEASUREMENT
C1.1.2.1 Pricing Schedule
The quantities set out in the Pricing Schedule (sometimes referred to as the bill or schedule of quantities) are estimated quantities and are used
for the comparison of tenders and for awarding the contract. It must be clearly understood that only the actual quantities of work done, or
materials supplied, will be measured for payment and that the scheduled quantities may be increased or decreased as provided for in the
Contract Documentation.
C1.1.2.2 Measurement of completed work

a) Units of measurement
All work shall be measured in accordance with the SI System of metric units.
b) Calculation of quantities
All distances along the centre line of the road as shown on the drawings are horizontal distances. These horizontal centre line distances will be
used in calculating the quantities of fill and pavement layers, as well as other items of work where applicable, for purposes of payment. All
cross-sections shall be taken in a vertical plane.
All materials which are specified to be measured in a vehicle shall be hauled in vehicles of such type and size that the actual volume may be
readily and accurately determined. Unless all vehicles are of uniform capacity, each vehicle shall bear a plainly legible identification mark
indicating its specific approved capacity.
The quantity of bituminous materials to be paid by volume shall be measured at the specified application temperature.
All quantities shall be measured to two decimal places.
c) Measurement of structures
Quantities shall be calculated from the dimensions shown on the drawings or as authorised by the Engineer.
No deduction in volume measured for payment shall be made for the volume of any individual, or closely grouped, reinforcing steel bars,
inserts, pipes and conduits which have a cross-sectional area up to and including 20 000 mm2 and which are embedded in the concrete.
d) Measurement of the depth of trenches and foundation excavations
Where trenches or foundation excavations are required below the level of mass excavations for the road prism, the depth of excavation of the
trenches or foundations shall be measured along the centreline of the trench from the resultant ground level after completion of the mass
excavation, unless the Engineer is satisfied that the excavation of the trenches or foundations from the original ground level or any lower level
was unavoidable. Where trenches are excavated in accordance with the fill method in the completed or partly completed road prism, the depth
of excavation shall be measured along the centreline of the trench from the levels at which the Engineer instructed the Contractor to commence
trench excavations.
e) Measurement of monthly paid items
All items of work which are paid per month shall be paid for the month, or part thereof, during which the item has to be provided in terms of the
Contract Documentation and/or as ordered by the Engineer. Measurement of any monthly paid items which have not been completed by, or
which still have to be provided after, the contractual time for completion of the Works, or of the relevant section of the Works, shall not be paid
for unless otherwise approved by the Employer.
C1.1.3 PAYMENT
C1.1.3.1 Contract rates
a) Computation of payment and applicability of contract rates
In computing the final contract amount, payment shall be based on the actual quantity of authorised work done in accordance with the
specifications, instructions and drawings. The contract rates shall apply, subject to the provisions of the Contract Documentation, irrespective of
whether the actual quantities are more or less than the scheduled quantities.
b) No rate or price entered in the Pricing Schedule
Where no rate or price has been entered against a pay item in the Pricing Schedule by a Contractor, it shall be accepted that no compensation
for such work is required, or will be paid, regardless of the final measured quantity of any work described in that pay item being required and
carried out.
c) No pay item entered in the Pricing Schedule
Where, a pay item described in this Standard Specification does not appear in the Pricing Schedule for a specific contract it means that the pay
item should not be required for that specific contract. However, if any item of work that is not included in the Pricing Schedule is required, and is
approved by the Engineer, the Contractor shall receive reasonable compensation for such work unless anything to the contrary has been
determined elsewhere. The compensation shall be determined in accordance with the provisions of the applicable Conditions of Contract with
respect to additional work.
d) Prime cost and provisional sums
Any prime cost or provisional sums shall be paid in accordance with the provisions of the applicable Conditions of Contract.
C1.1.3.2 Rates to be inclusive

a) Inclusivity of rates
The contract rates in the Pricing Schedule shall include for all costs incurred for executing and completing the Works as specified, for procuring,
furnishing, placing and installing all materials, for procuring and providing labour, supervision, construction equipment, tools, wastage, transport,
loading and off-loading, handling, maintenance until the item of work is taken over by the Employer, temporary work, testing, quality control
including process control, overheads, profit, risk and other obligations and for all other incidentals which may not be shown separately in the
Pricing Schedule but are necessary for the completion of the Works.
b) Rates to include for work carried out under partial width construction conditions and in restricted areas
No additional compensation shall be made for any work that is carried out under partial width construction conditions or is constructed in
restricted narrow, short and/or confined areas. Payment shall be made strictly in accordance with the applicable contract rates.
The Contractor shall take full cognisance of all the information given in the Contract Documentation, the nature of the Works and the conditions
on the Site of the Works before submitting his contract rates and, in doing so, the Contractor shall ensure that all additional costs associated
with partial width construction or construction in restricted narrow, short and/or confined areas, including all costs that are associated with any
changes in construction methods or techniques, construction equipment, additional labour and supervision personnel, reduced productivity and
increased inefficiencies, are included in the contract rates for the relevant applicable items of work.
This Clause shall apply in full to all pay items except where these requirements may be specifically amended in each case in the Contract
Documentation.
C1.1.3.3 Procurement, furnishing and placing material

a) Procuring and furnishing ... (material)
Where any of the words "supply", "procure", "provide", "provision of" or "furnish (material)" are used in the description of a pay item, it shall
mean the supply and delivery to the point of use of all materials of any kind required for the work covered by the particular pay item, including all
tax, purchase costs, claims, damages, royalties and all loading and transport costs involved, except where specific pay items for loading and/or
hauling the material are provided in the Pricing Schedule for that particular contract.
b) Placing material
The phrase "placing material" shall mean the off-loading, spreading, blending, processing / in-situ recycling, watering, mixing, shaping and
compacting (where specified) of the material required to construct the Works, as well as the procuring, furnishing, and applying and admixing of
water; the breaking-down of oversize material, the removing of oversize material which cannot be broken down, correcting irregular or uneven
surfaces or layers, the thickness of which is not to specification, finishing-off within the specified tolerances and to the specified surface finish,
the refilling of test / sampling holes and protecting and maintaining the completed work. In the case of asphalt layers and bituminous seals, it
shall also mean the heating and spraying of binder, the spreading of aggregate or asphalt mixtures, rolling, compacting, finishing-off to within the
specified tolerances, and protecting and maintaining the completed work.
The phrase "procuring, furnishing and placing" shall mean procuring and furnishing in addition to placing, all as defined above.

C1.1.3.4 Pay item descriptions
The descriptions under the pay items in the various Chapters of this Standard Specification, indicating the work for which allowance shall be
made in the contract rates for such pay items, are for the guidance of the Contractor and do not necessarily include or repeat all the details of
work and materials required by and/or described in the Standard Specification.
The pay item descriptions shall be read in conjunction with the relevant specifications and drawings, and the contract rates in the Pricing
Schedule shall be inclusive as specified in Clause C1.1.3.2 above.
C1.1.3.5 Payment for materials on the site

Payment for materials on site shall be made as provided for in the Contract Documentation for procured materials on the site which have not yet
been incorporated into the Works subject to the submission of acceptable proof of payment for the relevant materials. Proof of delivery to site
shall not be acceptable as proof of payment for the materials. Where not specified in the Contract Documentation payment will be calculated at
80 % of the materials purchase price, or, in the case of crushed stone which has not been purchased but has been produced on the site, at 80
% of a fair evaluation of the cost of providing such crushed material on site.
The Employer may, at his sole discretion, allow payment under "materials on the site" in respect of articles manufactured and stored off site,
subject to the submission of acceptable proof of payment for the relevant materials, subject to the submission of acceptable proof of their
ownership as being that of the Contractor and subject to the articles being clearly marked with the Contractor's name, the contract number and
other particulars in accordance with the Engineer's instruction.
Where payment of 80 % of the materials purchase price has been made by the Employer, the ownership of the material shall be transferred to
the Employer.
C1.1.3.6 Rate-only items

An item in the Pricing Schedule against which no quantity is given but a rate only is required, the Contractor shall fill in a rate or amount which
will constitute payment for work which may be done in terms of this item. Such a rate-only item is used where it is estimated that little or no work
will be required under the item, or where the item is to be considered as an alternative for another item where a quantity is given, or for
variations in rates of application or mix proportions in terms of Clause C1.1.4.
Work under rate-only items will be paid for only if the work has been executed in terms of a written instruction issued by the Engineer.
C1.1.3.7 Payment items from different Sections

In the Contract Documentation, whenever a payment item is specified in a particular Section and required to be used in another Section of the
Pricing Schedule then the relevant payment item number will be preceded by a reference to the Section in which it is being used.
For example, the loading and hauling payment items from Section C1.7 may be inserted into the Pricing Schedule for the loading and hauling of
the material required for the pavement layers which are paid for under the payment Section C5.3 as follows:
C5.3/1.7.1.1 Loading from stockpile cubic metres (m3)
C5.3/1.7.2.1 Hauling material for use in the Works and off-loading it on the site of the Works cubic metre kilometres (m 3-km)
C1.1.3.8 Reduced payments and penalty/damage amounts with respect to the contract price
adjustment amount
Where provision for reduced payments, or for the deduction of penalty or damage amounts, is made in the Contract Documentation, such
reduced payments shall not be deducted from the value of work done in calculating the contract price adjustment amount.
C1.1.4 VARIATION FROM SPECIFIED NOMINAL RATES OF APPLICATION OR FROM

NOMINAL MIX PROPORTIONS
The various Sections of these specifications specify nominal rates of application or nominal mix proportions for materials such as bituminous
materials, aggregates, fillers, stabilizing agents, paint and the like. The contract rates are based on these nominal rates of application and mix
proportions.
Where such nominal rates of application or nominal mix proportions are specified, provision is made for deviations in the quantities of material in
consequence of the rates of application or mix proportions specified by the Engineer in each particular case in consideration of the available
materials and the conditions on the site.
Where the actual rates of application or nominal mix proportions used in the Works vary from the specified nominal rates and mix proportions,
adjustment of compensation will be made either:
• as a payment to the Contractor in respect of any authorised increase in quantities which exceed those specified nominal rates of
application or mix proportions (including tolerances), where such increase has been specified by the Engineer or
• as a refund to the Employer in respect of the decrease in quantities which are less than those specified nominal application rates or mix
proportions (including tolerances), irrespective of whether such decrease results from an authorised decrease in the rates of application
or mix proportions, or from unauthorised reductions on the part of the Contractor.
Payment for a prescribed rate of application or mix proportion shall be based on the actual rate of application or mix proportion used, provided
that this does not exceed the prescribed rate of application or mix proportion, including any tolerance in the rate of application or mix proportion
which is included in the Contract Documentation. If the actual rate of application or mix proportion exceeds the prescribed rate or proportion, no
additional payment shall be made above the allowed tolerance limit. If the actual rate of application or mix proportion is below the prescribed
rate of application or mix proportion payment shall be based on the actual rate of application or mix proportion regardless of any tolerance
allowed. Notwithstanding the above, the Engineer shall be fully entitled to reject work which has not been constructed in accordance with the
specifications or the rates of application or mix proportions prescribed in the Contract Documentation or by the Engineer.
The Employer shall be refunded for any decrease in the specified rates of application or mix proportions at the same rate per unit of
measurement as the contract rate for additional materials required by an increase in the rates of application or mix proportions.

D1.1 GENERAL PREAMBLE
CONTENTS
D1.1.1 SCOPE
D1.1.2 GENERAL
D1.1.3 PERFORMANCE GUARANTEE REQUIREMENTS
D1.1.4 FUNCTIONAL PERFORMANCE ASSESSMENTS
D1.1.5 VISUALLY ASSESSED PROPERTIES
D1.1.6 INSTRUMENTALLY ASSESSED PROPERTIES
D1.1.7 EVALUATION FOR ACCEPTANCE
D1.1.8 ADDITIONAL PROCEDURES TO BE ADOPTED IN THE EVENT OF FAILURE
D1.1.9 NOTIFICATION OF REMEDIAL WORK
D1.1.10 REMEDIAL WORKS
D1.1.1 PREAMBLE
The requirements for any performance guarantees and/or compliance certificates are specified in Part D of each Chapter where applicable.
All product quality / performance / safety certificates issued by the South African Bureau of Standards (SABS) and by Agrément South Africa (ASA)
will be accepted.
Product quality / performance / safety certificates issued by testing authorities based in foreign countries will only be accepted if specified in the
Contract Documentation or at the discretion of the Employer.
Clauses D1.1.2 to D1.1.10 are not applicable to this Section.

1.2 GENERAL REQUIREMENTS AND PROVISIONS
CONTENTS
A1.2.1 SCOPE
A1.2.2 DEFINITIONS
A1.2.3 GENERAL
A1.2.4 DESIGN BY CONTRACTOR / PERFORMANCE BASED SYSTEMS
A1.2.5 MATERIALS
A1.2.6 CONSTRUCTION EQUIPMENT
A1.2.7 EXECUTION OF THE WORKS
A1.2.8 WORKMANSHIP

PART D GUARANTEES AND COMPLIANCE CERTIFICATES
A1.2 GENERAL REQUIREMENTS AND PROVISIONS

A1.2.1 SCOPE
This Section covers matters which relate to this Standard Specification and/or the Contract Documentation as a whole. It establishes generic
requirements that may also be applicable to other sections of this Standard Specification to avoid repetition in the other sections.
It includes payment items for general items that are not included elsewhere in this Chapter 1 or in the other Chapters and for dayworks that are
applicable to all the Chapters.
A1.2.2 DEFINITIONS
Acceptance Quality Control - encompasses those actions carried out by the Employer and/or the Engineer to inspect, sample, test and
measure each constructed part or section of the Works to determine whether the quality and workmanship is acceptable in terms of the
Specifications.
Process Quality Control - encompasses those actions carried out by the Contractor to assess and control materials and construction
processes to ensure that the quality of the final product/s meets all the specified requirements. It includes a quality plan with defined actions,
inspections, sampling, testing and measurement for each construction process to ensure that the quality control process is carried out
effectively.
Stakeholder liaison - the process whereby the Employer and the Contractor engage with interested and affected parties, in particular the local
authorities, local residents, schools etc., in order to inform them how the Works will affect the local community, to discuss how any adverse
effects of the Works on the local community and/or environment can be eliminated or alleviated and to provide any health and safety information
that is relevant to the local community regarding construction of the Works.
A1.2.3 GENERAL
The following Clauses include specifications for various general items which are not included in any of the other specific Chapters and Sections.
A1.2.3.1 Contractor's activities in respect of property outside the road reserve provided by the
Employer
The Contractor may occupy and make use of property outside the road reserve that is provided by the Employer for purposes of executing the
contract, on condition that:
• The Contractor complies strictly with the requirements of such statutory provisions, particularly with respect to the matters relating to
serving written notice to the owner before the Contractor enters the property.
• The Contractor shall provide the Engineer with a copy of the written notice and inform the Engineer of any further consultations that may
have taken place, or additional agreements reached, with the property owner.
• The Contractor adheres to all the written agreements made by the Employer with owners of the property outside the road reserve in
respect of the following matters:
− The location, extent and use of borrow pits, haul roads, construction roads and bypasses outside the road reserve,

− any compensation paid by the Employer or the Contractor, if applicable, for land or materials taken or for land temporarily used or
occupied,
− the reinstatement of property occupied, used, damaged or destroyed, or compensation therefor in lieu of reinstatement,
− the procedures for the moving of fencing, services and any other items and
− any similar matter directly related to the Contractor's activities on the property.
The Contractor shall comply with all the environmental requirements and all other current legislation and regulations which are applicable to the
land outside the road reserve which is being used by the Contractor for carrying out the Works.
On completion of his operations the Contractor shall obtain from the owner concerned a written statement to the effect that:
• The Contractor has fulfilled his obligations under any written agreement that the Employer has made with the owner.
• The owner is satisfied that all property occupied, including borrow pits, haul roads and construction roads, has been properly restored
and is in a satisfactory condition.
• With respect to fences, services or any other items moved, altered, damaged or affected in any way the owner is satisfied that
everything has been handed back to him by the Contractor in a satisfactory condition.
All such statements shall be signed and dated and copies shall be delivered to the Engineer. The obtaining of any such written statements will
not relieve the Contractor of the execution of any of his obligations to the satisfaction of the Employer or the owner or authority concerned.
A1.2.3.2 Contractor’s activities in respect of property which is not provided by the Employer
Should the Contractor use property which is not provided by the Employer, for haul roads, site offices and workshops, the Engineer’s offices and
laboratory, or for storing of equipment or materials required for construction or disposal, it shall be subject to the following:
• The Engineer shall agree to the use of any property selected for this purpose.
• Such property shall be physically separated from any production plant or activities and suitably fenced in.
• The area used for the aforesaid purpose shall be surveyed, and, where the land does not belong to the Contractor, he shall sign a lease
agreement with the owner of such property in respect of the full period for which such property shall be used for such purpose. The
lease agreement shall stipulate that the property owner shall not have any right whatsoever to any material stockpiled on such property
during the duration of the contractual lease agreement.
• A lease agreement shall be concluded by the Contractor with the owner or owners of such property for the full period that such property
is required. The lease agreement shall provide for possible extensions to match the duration of the contract. The lease agreements shall
also provide for the contract being terminated by Contractor’s default or liquidation and the resulting possibility for the lease agreement
to be taken over by a succeeding Contractor.
• Copies of all lease agreements shall be submitted to the Engineer for comment prior to signature by the signing parties and copies of
the final signed agreements shall lodged with the Engineer. Notwithstanding the Engineer’s comments on the conditions of a lease the
Contractor shall be solely responsible for adhesion to the terms of the lease agreements.
• Suitable permanent reference beacons shall be placed next to any material storage area, at the cost of the Contractor, to demarcate the
storage area and, if applicable, for use by the Engineer for taking cross-sections for determining quantities.
• Only material that is to be used for the Works shall be stored on such property.
• The Contractor shall comply with all the requirements of the environmental and any other legislation which is applicable to the property
being used.
On completion of his operations, the Contractor shall obtain, from the owner concerned, a written statement to the effect that:
• The Contractor has fulfilled his obligations under any written agreement that he made with the owner.
• The owner has received all the compensation he is entitled to and is also satisfied that all property that was occupied, including borrow
pits, haul roads and construction roads, has been properly restored and handed over to the owner in a satisfactory condition.
• With respect to fences, services or any other items moved, altered, damaged or affected in any way the owner is satisfied that
everything that was affected has been handed back to him by the Contractor in a satisfactory condition.
All such statements shall be signed and dated and copies shall be delivered to the Engineer. The obtaining of any such written statements will
not relieve the Contractor of the execution of any of his obligations to the satisfaction of the Employer or the owner or authority concerned.
A1.2.3.3 Environmental management

The Contractor shall ensure that the project complies with all the requirements that have been set out in the Environmental Authorisation (EA),
the Environmental Management Plan (EMP), the Water Use Licenses (WUL) for the extraction of water as well as for working within a certain
distance of watercourses and their associated specific conditions and permits.
Before any construction may commence the Contractor shall ensure that he has a copy of all licenses and permits required in terms of the EA,
the EMP and for the WULs that were obtained by the Employer prior to the Contract being awarded. The Contractor shall also ensure that he
obtains all other outstanding permits required to comply with the requirements of the EA, the EMP and the WULs, in particular the WUL for the
extraction of the amount of water he requires from rivers and streams. The Contractor shall supply a copy of all required licenses and permits to
the Engineer for his records.
Where specified the Contractor shall carry out a search and rescue of environmentally sensitive/endangered vegetation and prepare all
necessary rehabilitation plans.
All Contractors are required to comply with all the applicable current rules, regulations, standards, policies and legislation, especially those
contained in the following Acts and in any subsequent amendments thereto:

• The National Environmental Management Act No. 107 of 1998 (regulates duty of care principle).
• The National Water Act No. 36 of 1998 (guides the management of water and its associated resources in South Africa).
• The National Environmental Waste Act 59 of 2008.
The Contractor shall carry out all the work in accordance with the environmental legislation and authorisations which are applicable to the
Contract. Permits are issued with stringent guidelines, monitoring procedures and other requirements and the Contractor shall ensure full
compliance with all of them.
All waste material shall be disposed of in accordance with the applicable legislation and requirements. The Contractor shall confirm what the
waste disposal requirements in the area are with the relevant provincial and local authorities before he commences his site establishment. The
Contractor shall have a written waste management and disposal plan which classifies the types of unsuitable and waste material on the site to
be disposed of and identifies the approved disposal sites. Hazardous waste must be collected and disposed of separately from general waste at
an approved hazardous waste site.
If specified in the Contract Documentation, the Contractor shall also provide a dedicated, full time environmental officer who will be responsible
for the environmental monitoring, compliance and reporting duties.
A1.2.3.4 Extension of time for delays caused by rainfall

This Clause specifies the conditions under which extensions of time for rainfall delays will be measured.
Any delays caused by rainfall shall be determined in terms of one of the three methods given below. The applicable method for a particular
contract shall be specified in the Contract Documentation. The rainfall delay determined by using the specified method shall entitle the
Contractor to an equivalent extension of the time for completion without the need for formal claim procedures. (If none of the methods given
below are specified in the Contract Documentation then any claims for rainfall related extensions of time will be dealt with according to the
applicable Conditions of Contract.)
Any other delays caused by exceptionally adverse weather conditions that have not already been taken into account as specified above shall be
dealt with in accordance with the applicable Conditions of Contract.
The Contractor shall take cognisance of all the temperature, wind speed, moisture content and curing related limitations and/or restrictions that
are applicable to some items of the Works as specified in the relevant clauses of this Standard Specification. No extensions of time will be
measured or granted for any delays caused by the Contractor’s compliance with these limitations and/or restrictions.
a) Method 1 (Rainfall formula)
If specified in the Contract Documentation the formula below shall be used to calculate separately the delay for each calendar month or part
thereof due to rainfall. It shall be calculated each month during the period referred to in the Conditions of Contract as the time for completion of
the Works (including any extension thereof that may have been granted), or until the issue date of the Taking-over Certificate, whichever is the
shorter period. The delay calculated for a given month shall be used to determine the interim extension of time granted for that month. At the
end of the applicable period referred to above, the aggregate of the monthly delays will be taken into account for the final determination of the
total extension of time for the Contract. Such determination will not be subject to normal claim procedures.
V = (Nw - Nn) + [(Rw - Rn)  X]
If any value of V is negative and its absolute value exceeds Nn, then V shall be taken as equal to minus Nn.
The delay for a part of a month shall be calculated by substituting pro rata values for the variables in the equation.
The symbols in the above rainfall formula shall have the following meanings:
V= Delay due to rain in calendar days in respect of the calendar month under consideration.
Nw = Actual number of days during the calendar month on which a rainfall of Y mm or more per day has been recorded.
Rw = Actual rainfall in mm for the calendar month under consideration.
Nn = Average number of days in the relevant calendar month, as derived from existing rainfall records provided in the Contract
Documentation, on which a rainfall of Y mm or more per day has been recorded.
Rn = Average total rainfall in mm for the calendar month, as derived from existing rainfall records supplied in the Contract
Documentation.
X= 20, unless specified otherwise in the Contract Documentation.
Y= 10, unless specified otherwise in the Contract Documentation.
Extension of time for rainfall shall apply in addition to any other approved contract extension of time due to other causes. The total delay that will
be taken into account for the determination of the total extension of time for the contract shall be the algebraic sum of the monthly totals for the
period under consideration calculated to one decimal, and the delay shall be applied to the contract duration after any other caused and
approved contract extensions of time have been applied. The total delay caused by rainfall shall not exceed the duration past the issue of the
Taking-over Certificate. Should the grand total be negative, the time for completion shall not be reduced on account of rainfall.
The total extension of time for any calendar month shall not exceed (Nc - Nn) calendar days, where Nc = the number of calendar days in the
month under consideration.
The factor (Nw - Nn) shall be considered to represent a fair allowance for variations from the average number of days during which rainfall
equals or exceeds Y mm per day.
The factor [(Rw - Rn)  X] shall be considered to represent a fair allowance for variations from the average for the number of days during which
rainfall does not equal or exceed Y mm per day, but when wet conditions prevent or disrupt work.
This formula does not take into account any flood damage, which could cause further or concurrent delays and which should be treated
separately in so far as extension of time is concerned. It also does not deal with other types of weather which may cause delays, for instance
snowfalls, abnormally strong wind and extreme temperatures. All such delays shall be dealt with separately in accordance with the terms of the
Conditions of Contract.

Accurate rainfall measurements shall be collected at a suitable point or various points on the site as approved by the Engineer and recorded
each calendar day at 08h00 unless otherwise agreed to by the Engineer. The Contractor shall, at his own expense, take all necessary
precautions to ensure that the rain gauges cannot be interfered with by unauthorised persons. Failure by the Contractor to submit and agree
such records in good time may prejudice his entitlement to extension of time on account of rainfall.
Information regarding existing rainfall records, if available from a suitable rainfall station near the site, will be supplied in the Contract
Documentation, together with calculations of rain delays for previous years in accordance with the above formula. The average of these delays
will be regarded as predictable normal rain delays which the Contractor shall accommodate in his programme, and for which no extension of
time will be considered.
If no suitable rainfall records are available, Method 1 will not apply.
b) Method 2 (Critical path method with consequential delays)
Where the critical path method with consequential delays is specified in the Contract Documentation for determining the extension of time
resulting from rainfall, it shall be applied as follows:
A delay caused by rainfall conditions will be regarded as a delay only if all progress on an item or items of work on the critical path of the
Contractor’s programme has been brought to a halt for part of a day or a full day. Delays on programmed and actually planned working days
only will be taken into account for the extension of time. Each day, or portion of a day so agreed will accrue as ‘n’ days of delay over the
duration of the contract. The summary of accrued agreed ‘n’ delays shall be recorded at each site meeting.
The Contractor shall make provision in the programme of work for an expected delay of "N" working days caused by predictable normal rainy
weather, for which the Contractor will not receive any extension of time. The value of "N" shall be given in the Contract Documentation.
Extension of time for rainfall delays which occurred during working days will be granted to the degree to which the agreed cumulative actual
delays, in full or part of working days as defined above, exceed the cumulative number of "N" workings days as mentioned in the Contract
Documentation, during the contract period up to the issue of the Taking-over Certificate. Extension of time for rainfall shall apply in addition to
any approved contract extension of time due to other causes.
This method does not take into account any flood damage, which could cause further or concurrent delays and which should be treated
If a delay due to wet conditions is caused by, or exacerbated by, the lack of adequate temporary drainage measures, such a delay shall not be
taken into account in the calculation of any extension of time.
Any delay due to rainfall will only be recognized and granted to the extent that the delay could not be mitigated by changing work sequences.
The delay shall be applied to the contract duration after any other caused and approved contract extensions of time have been applied. The
total delay caused by rainfall shall not exceed the duration past the issue of the Taking-over Certificate.
c) Method 3 (Critical path method without consequential delays)
Where the critical path method without consequential delays is specified in the Contract Documentation for determining the extension of time
resulting from rainfall, it shall be applied as follows:
Delays caused by rainfall may be considered as extension to the time for completion only if the Engineer agrees that the event (and not the
consequence of the event) occurred during the working day within the contract period and caused all progress on an item or items of work on
the critical path of the Contractor’s programme brought to a halt. Each day, or portion of a day so agreed will accrue as ‘n’ days of delay over the
duration of the contract. The summary of accrued agreed ‘n’ delays, which exclude any consequential delays as stated below, shall be recorded
at each site meeting.
No limitation is placed on the quantity, severity or duration of the rainfall event as being the cause of delay. Expressly excluded from the
measurement of ‘n’ days are consequential delays, which are taken to mean delays to critical path activities attributable to the rainfall event but
occurring after (i.e. outside of and distinctly separate from) the duration of the rainfall event itself.
The Contractor shall make provision in the Contractor’s programme of work for expected “N” working days caused by rainfall. This provision
shall be shown as a terminal float on the Contractor’s programme. The value of "N" shall be given in the Contract Documentation.
Any extension to the time for completion caused by rainfall delays will only be considered once the agreed cumulative ‘n’ delays during the
contract period up to the issue of the Taking-over Certificate exceed “N” working days. Extension of time for rainfall shall apply in addition to any
approved contract extension of time due to other causes.
This method does not take into account any flood damage, which could cause further or concurrent delays and which should be treated
The delay shall be applied to the contract duration after any other approved contract extensions of time have been applied. The total delay
caused by rainfall shall not exceed the duration past the issue of the Taking-over Certificate.
A1.2.3.5 Handing-over of the Site of the Works

The Site of the Works will be handed over to the Contractor for construction purposes, subject to such conditions as may be specified in the
Contract Documentation regarding matters such as:
• The sequence in which sections of the Works will be handed over and must be completed.
• The maximum total length of temporary deviations that will be allowed to be in operation at any time.
• The number of half or partial width construction sections that will be permitted on the Site of the Works at any one time.
• The minimum length of existing or newly completed full width, unrestricted road sections that must be open to traffic between any half or
partial width construction sections.
• Any other matters relating to the Contractor's use and occupation of the road reserve.

A1.2.3.6 Health and safety
The Contractor shall always comply with the requirements of the health and safety plan, drawn up by the Contractor in compliance with all
current and applicable health and safety legislation, the Employer’s health and safety specification and the Contractor’s own health and safety
requirements to ensure that the Contractor complies fully with all current legislation and regulations as well as with any additional health and
safety requirements that may be specified in the Contract Documentation. The Contractor’s health and safety plan shall be developed to
address all risks specific to the Works as identified in risk assessments carried out by the Contractor and/or by the Employer.
The Employer and /or his construction health and safety agent may also monitor the Contractor’s compliance with the requirements stipulated in
the Employer’s health and safety specification as well as the requirements set out in the Contractor’s health and safety plan.
A1.2.3.7 Legal and contractual requirements and responsibility to the public and the Employer
The Contractor shall comply with all the legislative and regulatory requirements of all the relevant statutory bodies pertaining to his site
establishment and to the execution of the Works. The Contractor shall also comply with the requirements given in the Contract Documentation
and with his legal and general obligations to the public, particularly with regard to obtaining and maintaining all the insurances and sureties
required for the duration of the Contract and the Defects Notification Period.
A1.2.3.8 Tolerances
The work specified in all the chapters of this Standard Specification shall comply with the various dimensional and other tolerances specified in
each case. No representation is made that the full specified tolerances will be available independently of each other, and the Contractor is
cautioned that the liberal or full use of any one or more tolerances may deprive him of the full or any use of tolerances relating to other aspects
of the work. The latter would apply particularly in respect of level tolerances on layer work and the related requirements regarding layer
thicknesses.
Where no tolerances are specified, the standard of workmanship shall be in accordance with normal good practice.
A1.2.3.9 Monthly reports

The Contractor shall prepare monthly reports on progress, delays incurred, plant returns, OHS and EMP compliance, staff training,
empowerment, capacity building, small Contractor development, labour and staff returns and any other information required by the Employer
and/or the Engineer which is specified in the Contract Documentation.
The Contractor’s monthly reports shall be submitted to the Engineer at least two working days prior to the applicable scheduled monthly site
meetings.
A1.2.3.10 Notices, signs and advertisements

The Contractor shall not erect any signs, notices or advertisements on the Works or the site of the Works without the written approval of the
Engineer.
Details of the official contract sign boards (if any) that should be erected will be given in the Contract Documentation or issued by the Engineer.
These signs are to be erected in positions determined by the Engineer not later than one month after the Contractor has been given access to
the site. They shall be maintained in a clean and legible condition throughout the contract and removed immediately upon completion of the
Works.
No signboards other than those specified above will be permitted on or adjacent to the Works, except that the Contractor may permit each of his
subcontractors to display one signboard, and one only, of less than 2 m² at the Works office. All advertisements, notices and temporary signs
shall be removed by the Contractor immediately upon completion of the Works.
A1.2.3.11 Ordering of daywork

Daywork shall be undertaken strictly in accordance with the provisions of the Conditions of Contract. No daywork shall be undertaken unless
specified by the Engineer. Such a written instruction shall include a full description of the work to be carried out. Before commencing any
daywork the Contractor shall obtain the Engineer’s agreement regarding the estimated duration of the dayworks, the numbers of each category
of staff to be employed, the materials to be used and the construction equipment and vehicles that will be required to carry out the work.
The Contractor shall provide the Engineer with a daily report that records the actual duration, numbers of staff and materials, equipment and
vehicles used each day for approval of the dayworks.
A1.2.3.12 Ownership of assets and disposal of non-useable assets

Unless otherwise stated in the Contract Documentation the Employer is the owner of all existing moveable and immoveable assets in the road
reserve.
Non-useable assets are assets that have reached the end of their economic life, are no longer needed or need to be replaced. A disposal plan
for these non-useable assets will be given in the Contract Documentation. The Contractor shall submit rates for the disposal of each of the
identified non-useable assets listed in the Contract Documentation. The tendered rates could be positive or negative depending on the cost of
disposing of them against the value that the Contractor may wish to place upon them.
A provisional sum may also be provided to cover the cost of the disposal of any non-useable assets that may be identified during the
construction of the Works. A record must be kept of all such non-useable assets that are disposed of. Any income derived from the sale of
these assets will be offset against the provisional sum.
A1.2.3.13 Prevention of damage to nearby properties and services

All buildings that could be affected by excessive ground vibrations generated during the construction operations will be identified in the Contract
Documentation, or by the Engineer, and categorised in accordance with the descriptions given in Table A1.2.3-1 below.
Before commencing any construction work on the site of the Works which involves the use of vibratory or impact compaction equipment,
pavement breakers, piling equipment, pneumatic drills and hammers and excavators or overhead cranes in the vicinity of any public or privately
owned buildings the Contractor shall arrange with the property owner for an inspection, and, if permitted by such owner, a photographic survey,
of all the items on the property that could be affected by the construction equipment and/or construction processes that the Contractor intends to
use.

Written and photographic records must be made of any existing defects, cracks or any other potential weaknesses and the Contractor shall
discuss with the property owner and record in writing what preventive and/or mitigation measures that will be taken to avoid or prevent any
damage from occurring to the items on the property as a result of the construction work. The Contractor and the property owner should sign and
date these records and a copy shall then be submitted to the Engineer for comments if required and for record purposes.
The Contractor shall prepare a written and photographic record of any overhead services or other obstructions on or near the property
boundaries such as power lines, telephone lines, fences, walls, signage etc. that could be affected by the construction activities, in particular by
cranes, excavators and similar construction equipment that could encroach on the property. These records shall be given to the Contractor’s
safety officer and the relevant safety plans shall be amended to include preventative measures for any damage to property or any injuries to the
Contractor’s personnel and members of the public that could occur.
The Contractor shall note the presence of any underground pipelines which may be affected by the construction activities, in particular jointed
pipes. The Contractor shall comply with the provisions of Clause A2.3.1.2d)(ii) of Chapter 2 with respect to the location and protection of existing
services. All vulnerable underground services shall be exposed by hand excavation so that their condition and potential vulnerability to heavy
vibrations can be assessed. The Contractor shall discuss with the relevant service authority and record in writing what preventive and/or
mitigation measures will be taken to prevent any damage to the vulnerable services that could occur due to the proposed compaction or blasting
operations. The Contractor and the service authority owner should sign and date these proposed preventive and/or mitigation measures and a
copy shall then be submitted to the Engineer for comments if required and for record purposes.
The Contractor shall use suitable construction equipment and/or modify the working methods to ensure that the maximum peak particle
velocities generated by the construction equipment, as measured on the ground surface with a triaxial seismograph vibration monitor placed at
the corner of the building closest to the source of the vibration, or directly above the pipeline, do not exceed the values given in Table A1.2.3-1
below:
Table A1.2.3-1: Peak particle velocity limits
STRUCTURE / PIPELINE TYPE AND CONDITION MAXIMUM PEAK PARTICLE VELOCITY (PPV)
(mm/sec measured at a frequency of 50 Hz)
Fragile buildings (old and / or poorly constructed) 2,5
Old or low quality houses 5,0
Well built houses 12,5
Concrete structures 12,5
Industrial buildings 12,5
Steel pipelines 15,0
uPVC pipelines 10,0
Asbestos cement / fibre cement pipelines 5,0
NOTE: The PPV values given in the above table are subject to review during the period that this Standard Specification is still published as a
Draft Standard.
At the start of any work involving equipment that will generate ground vibrations all vulnerable structures must be monitored closely by the
Contractor. If there are any signs that any damage is being caused by the ground vibrations the work shall be stopped immediately and the
Engineer shall be informed. The level of the ground vibrations generated at the closest corner of the affected building shall then be measured
and checked against the allowable limits given in Table A1.2.3-1 above. The Engineer shall then decide if work may continue of if the Contractor
must alter his working methods to reduce the ground vibration levels.
Any damage that may occur to buildings, structures, fencing, walls, services and anything else on the property that may be affected by the
construction activities shall be repaired or rectified to the satisfaction of the owner at the Contractor’s expense unless the Engineer is satisfied
that all the necessary and specified precautions were taken by the Contractor and the damage was unavoidable.
A1.2.3.14 Remedial work

The Contractor shall replace, repair or make good any part of the Works or any equipment or material that is found not to conform to the
specified requirements, or is damaged so that it no longer conforms to the specified requirements, in accordance with the Conditions of Contract
before the Taking-over Certificate will be issued.
A1.2.3.15 Routine maintenance

In addition to the Contractor’s maintenance responsibility stemming from his obligations under care of the Works, the Contractor shall also be
responsible for all routine maintenance of the public roads within the site of the Works and other public roads being used as detours from the
date of handing over of the site until the completion of the Works. This routine maintenance responsibility shall include all the maintenance of all
existing roads, road furniture, fixtures and the like and shall typically comprise grass cutting, rubbish removal, the clearing and repair of existing
drainage systems, repair of existing guardrails and signs, patching, assistance with clearance at accident scenes and attending to any structural
damage caused by traffic during the contract period.
In circumstances where another Contractor has been appointed by the Employer to carry out routine maintenance activities over the same
section of the road, the Contractor may be required to attend meetings with the routine maintenance contractor to co-ordinate maintenance
activities.
The potential exists for an agreement to be reached whereby the routine maintenance contractor may continue to perform certain
responsibilities such as the cutting of grass and the collection of rubbish, in which event the Contractor shall make allowance in his construction
activities and Works programme to accommodate the routine maintenance contractor and to provide reasonable access to allow him to carry out
such work.
A1.2.3.16 Site meetings

The Contractor shall attend regular (at least monthly) meetings on the site with the Employer and the Engineer, at dates and times to be
determined by the Employer and/or the Engineer. Such meetings will be held for evaluating the progress of the Works, compliance with the
environmental management and the health and safety regulations and for discussing matters pertaining to the contract which any of the parties
represented may wish to raise. To this effect the Contractor will be obliged to compile a formal monthly report, drafted in consultation with the
Engineer where necessary, and to submit these monthly reports to the Engineer at least two working days before each site meeting.

A1.2.3.17 Site security
The Contractor is responsible for keeping unauthorised persons off the Site of the Works in accordance with the requirements of the Conditions
of Contract. The Contractor shall therefore carefully assess the security measures of whatever nature that may be required at the location of the
Engineer’s site office and laboratory, the Contractor’s offices, stores and workshops, the Site of the Works including quarries, borrow pits,
stockpile sites and manufacturing yards as well as any traffic accommodation site facilities and equipment which may be placed on the
approaches to / exits from the Site of the Works.
The Contractor shall then make all necessary arrangements to provide adequate security measures which will prevent access to the Site of the
Works and to the Contractor’s and Engineer’s site facilities by any unauthorised persons and will also prevent damage to, or theft of, any
facilities, equipment, plant, materials and parts of the Works which have not yet been handed over to the Employer.
The security measures provided for the Engineer’s site offices and laboratories, and for the Engineer’s site accommodation situated on or
adjacent to the Site of the Works, shall include security fencing and gates, security lights and burglar alarm systems linked to an armed
response company and a night watchman.
The security measures provided for the Engineer’s rented housing shall consist of an acceptable burglar alarm system linked to an armed
response company.
A1.2.3.18 Stakeholder liaison

The initial stakeholder liaison required will normally be undertaken by the Employer and/or the Engineer. The outcomes and agreements
resulting from all such stakeholder liaison will be taken into account and included in the Contract Documentation. This process may involve the
establishment of a Project Liaison Committee (PLC) and the employment of a Project Liaison Officer (PLO) by the Employer.
When the Contract has been awarded the Contractor shall undertake further stakeholder liaison to develop and manage relationships with all
stakeholders, communities and individuals who are, or who may be, impacted by the Works. The stakeholder and community liaison shall be
carried out in accordance with the Employer’s social facilitation principles and processes where provided.
The Contractor shall also identify all other potential stakeholders in addition to those already identified in the Contract Documentation.
Stakeholders include the road users who will be affected by the Works, pedestrians and non-motorised traffic that may need to traverse or cross
the site of the Works as well as some or all of the following persons, parties or entities:
• Relevant Provincial departments.
• Relevant Municipal departments.
• Traditional authorities.
• Community interest groups.
• Organised youth representation.
• Organised women representation.
• Organised disabled people representation.
• Organised labour representation.
• Other structured community groups such religion, education, farming, etc.
• Transport industry forums, e.g. Bus and taxi organisations.
• Business sector forums.
• Road user forums.
• Ratepayers organisations.
• Environmental interest groups.
• Road safety interest groups.
• Ward committees.
• Any other recognised relevant and representative structure.
As part of the stakeholder liaison process the Contractor shall:
• Listen to and record the stakeholder’s concerns regarding how they may be affected by the Works and to inform them on what
measures the Contractor can and will take to alleviate their concerns and mitigate any adverse effects of the Works that are identified.
• Inform and educate all affected parties about the safety risks associated with the Works in so far as the Works will impact on the local
road users, residents and school children.
The Contractor shall analyse the influence of all stakeholders on the project and develop strategies to communicate with them and to manage
competing expectations so that he can mitigate issues that would otherwise delay the project. All stakeholders shall be provided with relevant
information about the Works via community meetings, newspaper advertisements, radio broadcasts, electronic communication media and
information leaflets as appropriate.
Where a PLC has been established by the Employer, the Contractor shall use the PLC as the official communication channel, with the
assistance of the PLO where one has been appointed by the Employer/Engineer. The Contractor shall delegate someone to participate in the
PLC meetings and to assist and/or hold the PLC accountable for the organisation of community meetings and the effective dissemination of
relevant information to all stakeholders and affected communities.
The stakeholder liaison process may also include issues related to the employment of local labourers and sub-contractors chosen by the
Contractor and/or employed in accordance with any targeted labour recruitment and/or targeted enterprises selection requirements that may be
specified in the Contract Documentation. All labour and sub-contractor related matters, and any associated risks, are and shall remain the
responsibility of the Contractor irrespective of the Employer’s and/or Engineer’s role/assistance provided in establishing a PLC and/or providing
a PLO.

A1.2.3.19 Temporary drainage and dewatering
The Contractor shall be responsible for the provision of temporary drainage works such as drains, open channels, banks etc., and for providing
and operating temporary pumps and such other equipment as may be necessary for adequately protecting, draining and dewatering the Works
and any temporary Works, deviations and detours on existing roads if required.
The Contractor shall ensure that any temporary drainage works and/or dewatering operations do not cause erosion or flooding of other parts of
the Works or adversely affect the stability of any excavated trenches or slopes. If the Contractor becomes aware of any potential signs of slope /
trench instability he shall immediately suspend the work and withdraw all personnel from the area and fence and/or barricade it to prevent
access. The Contractor, who remains responsible for compliance with the OHS regulations, shall then propose, design and implement all
measures required to rectify the situation.
Unless specifically reflected in the pricing schedule, all such measures shall be deemed to be included in the rates for the Works.
A1.2.3.20 Road safety audits

If stated in the Contract Documentation, two types of road safety audits shall be carried out on the Contract, namely a work zone traffic
management audit before any construction work commences and a pre-opening stage road safety audit when the construction work is almost
complete.
a) Work zone traffic management audit
Before any construction work commences the Contractor shall appoint an independent qualified road safety auditor to carry out an audit which
shall be undertaken in terms of the requirements given in the latest version of the South African Road Safety Audit Manual (SARSAM) for a
Stage 4 construction work zone traffic management audit.
The auditor / audit team shall, when carrying out this audit, recognise the guidance given to contractors in the South African Road Traffic Signs
Manual, Volume 3, Chapter 13 as well as the traffic accommodation specifications given in Section A1.5 of this Chapter.
Particular attention shall be paid to the following aspects:
• The appropriateness of the proposed traffic management scheme, especially in transition areas.
• Adequacy of the advance warning arrangements.
• Proposed work zone speed limits.
• Conflicts between permanent and temporary road signs and any other road features.
• Any aspects of the proposed signage, barrier and detour layouts that could possibly be misread by / be confusing to road users or may
violate normal driver expectancy.
• The likelihood of dust and/or mud obscuring safety signage.
• The appropriateness and adequacy of any proposed vehicle restraint systems / barriers, the installation thereof and the safety of the
terminals.
• Adequate provision for pedestrians and public transport vehicles if applicable.
• Conflict points between construction vehicles and the public road users.
• The effect, and mitigation of, traffic congestion during peak periods.
• The effect of an accident if it occurs within the deviation areas.
b) Pre-opening stage road safety audit
Just before the construction work is completed the Contractor shall appoint an independent qualified road safety auditor to carry out an audit
which shall be undertaken in terms of the requirements given in the latest version of the South African Road Safety Audit Manual (SARSAM) for
a Stage 5 pre-opening stage road safety audit.
The auditor / audit team shall, when carrying out this audit, recognise the guidance given to contractors in the South African Road Traffic Signs
Manual, as well as the construction specifications for road signs, guardrails and road markings given in Chapter 11 of this Standard
Specification.
Particular attention shall be paid to the following aspects:
• Has sufficient provision been made for all the different users of the road project?
• Has adequate protection been provided for all potential roadside hazards?
• Are there any variations between the approved design and the constructed Works which may adversely influence the safety of the road
users?
• Are all the road signs, road markings, road furniture and lighting arrangements, if applicable, correctly erected and positioned in
accordance with the specified requirements and do they meet the required specified standards?
• Have all temporary traffic accommodation arrangements, construction equipment and construction materials / debris that may be a
direct physical hazard or may cause any road user confusion been removed or safely repositioned?
A1.2.3.21 Water
The Contractor shall make his own arrangements for procuring, transporting, storing, distributing and applying the water needed for construction
and other purposes, except where otherwise specified.
Obtaining water from streams, rivers, dams or boreholes shall be subject to the Contractor obtaining the required permit from the relevant
authority.
Obtaining water from a municipal or other water supply authority shall be subject to the Contractor entering into a supply agreement with the
relevant supply authority.

The suitability of water for construction purposes shall be determined in accordance with the acceptance parameters given in the following
clauses of this Standard Specification:
• Water for backfilling trenches and for concrete required for services work – Clause A2.1.5.3 of Chapter 2.
• Water for testing pipelines – Clause A2.3.8.3b) of Chapter 2.
• Water for earthworks and pavement layers – Clause A4.1.5.18 of Chapter 4.
• Water for stabilisation of pavement layers – Clause A5.4.5.6 of Chapter 5.
• Water for concrete pavements – Clause A6.1.5.2 of Chapter 6.
• Water for diluting bitumen emulsion – Clause A10.1.5.6 of Chapter 10.
• Water for grout – Clause A12.3.5.1 of Chapter 12.
• Water for shotcrete – Clause A12.5.5.4 of Chapter 12.
• Water for concrete structures – Clause A13.4.5.3 of Chapter 13.
• Water for cementitious repair mortar or concrete – Clause A14.4.5.3 of Chapter 14.
• Water for sprayed concrete – Clause A14.6.5.3 of Chapter 14.
A1.2.3.22 Wayleaves/Agreements and Permits

a) Wayleaves/Agreements (Planning and Design Approvals)
The Employer will be responsible for obtaining the necessary planning and design approvals for the work described in the Contract
Documentation or shown on the drawings. In terms of this Standard Specification such approval is deemed to be granted in accordance with the
terms of what are referred to as “wayleaves”. Before commencing any work the Contractor shall ask the Engineer to obtain all the applicable
wayleaves from the Employer.
If specified in the Contract Documentation, the Contractor shall be responsible for applying for certain wayleaves and, if so specified, the
Contractor shall determine and comply with the wayleave application processes specified by the road authority responsible for the road reserve
and by any other service authority/provider whose services are known to exist in the road reserve.
The applications for such wayleaves shall be submitted timeously by the Contractor to ensure that wayleaves can be issued before the work is
programmed to start. Applications for wayleaves shall be submitted with the relevant design drawings.
The Contractor shall pay all fees and charges for wayleaves to the road authority responsible for the road reserve or to any other service
authority/provider whose services exist in the road reserve.
The Contractor shall comply with all conditions pertaining to the approval of wayleaves that may be imposed by the road authority or by the
relevant service provider.
b) Permits and other approvals (Construction or Work Permits)
The Contractor shall be responsible for obtaining the necessary approvals, permissions or authorisations to carry out the work described in the
Contract Documentation. In terms of this Standard Specification such approvals, permissions or authorisations are deemed to be granted in
terms of what are referred to as “construction permits” or “work permits”. The Contractor shall be responsible for obtaining the necessary
construction or work permits from all the relevant road authorities or service authorities/providers whose services are known to exist in the road
reserve.
The Contractor shall determine and comply with the construction permit application processes specified by the road authority responsible for the
road reserve or by any relevant service authorities/providers.
The applications for construction and/or work permits shall be submitted to the relevant road authority or service authority/provider timeously to
ensure that construction permits can be issued before the Works are programmed to start. Applications for construction and/or work permits
shall be submitted with the relevant drawings.
The Contractor shall pay all fees and charges for construction and/or work permits to the road authority responsible for the road reserve or to
the relevant service authority/provider.
The Contractor shall comply with all conditions included in the construction and/or work permits that may be imposed by the road authorities or
by the service authorities/providers. Such conditions may include, but are not limited to:
• Giving adequate notice of commencement of work.
• Providing adequate supervision of the Works and compliance with health and safety regulations.
• Compliance with environmental and water use requirements.
• Providing access to and conducting progress inspections required by the road authority or service provider.
• Specific requirements for road and service crossings.
• Specific requirements for location of services and/or co-location of services for multiple service providers.
• Specific requirements for temporary and permanent reinstatement of services, road crossings etc. Provision of adequate notice of and
carrying out of inspections on completion of the Works.
• Provision of record drawings and documentation to the relevant authorities, service authorities/providers and to the Employer if required.
The Contractor shall familiarize himself with, and comply with, all local by-laws applicable to work in the road reserve.
Only work described in a construction/work permit may be done and only at the locations covered by the permit. The work described in the
permit shall commence and shall be completed within the period stipulated by the road authority or service authority/provider, failing which the
construction/work permit may lapse and re-application for the permit will then be required.

A1.2.3.23 Work in restricted areas
The Contractor shall programme the work and select the working methods and equipment taking due cognizance of all restrictive conditions
indicated in the Contract Documentation regarding the location, size and spacing of the various construction areas, any specific work sequences
that may be required and any traffic accommodation or other factors that may affect the programme of work.
As stated in Clause C1.1.3.2 no additional compensation shall be made for work that could be considered as partial width construction or for
construction in restricted narrow, short and/or confined areas unless otherwise specified in the Contract Documentation.

A1.2.4.1 Designs and drawings for the permanent Works provided by the Contractor
Where the Contractor is required to prepare any designs and/or drawings for the permanent Works they shall be prepared as specified below
and in accordance with any further requirements that may be specified by the Engineer. The drawings shall comply in all respects with the
requirements of the Employer. If provided by the Employer, the Contractor shall use the master standard drawing sheets and schedules as
masters for all drawings prepared by him and submitted to the Engineer for consideration.
The Contractor shall submit to the Engineer for comment two A0 paper copies of each drawing and all relevant design calculations prepared by,
or on behalf of, the Contractor and signed by a registered competent person. Electronic versions of the drawings and all relevant design
calculations should also be provided in the specified format. The standard of detailing and quality of print shall be the same as those of the
drawings supplied to the Contractor under the Contract Documentation.
Accepted designs and/or drawings shall form an integral part of the Contract Documentation. Any designs and/or drawings not accepted by the
Engineer will not be permitted on the site of the Works for construction purposes and/or used for the manufacture of any item. Notwithstanding
the acceptance and/or signing of the designs and/or drawings by the Engineer or the Employer, the Contractor shall take full responsibility for all
details, discrepancies, omissions, errors, etc. in respect of the said designs and/or drawings as well as for all consequences arising therefrom.
The Contractor shall submit only fully completed and checked designs and/or drawings in accordance with this Standard Specification and shall
not be entitled to claim for any delays resulting from the submission of incomplete or incorrect drawings. Unless already specified elsewhere in
the Contract Documentation, the Contractor shall agree with the Engineer the amount of time required by the Engineer to consider and
comment on the designs and/or drawings. The same time frame requirements will apply to any resubmissions of the designs and/or drawings
that may be required.
A1.2.4.2 Designs and drawings for temporary works provided by the Contractor
The Contractor shall be responsible for the design and execution of all temporary work and structures that are required for the construction and
completion of the Works. This includes all deviations, temporary drainage and flood diversion or control measures, drilling and blasting,
excavations, scaffolding, shuttering, shoring, support structures and all other work that is necessary for the construction of the permanent
Works.
The design of all such temporary work must be carried out by experienced persons who are suitably and, where required by legislation,
professionally qualified to carry out such designs. The Contractor shall ensure that the design of all temporary works has been carried out in
accordance with all relevant legislation and that the construction / erection of the temporary works is carried out by and supervised by
competent, experienced persons.
All design calculations and drawings required for the temporary works shall be submitted to the Engineer for comment when the Contractor is
requested to do so. Unless already specified elsewhere in the Contract Documentation, the Contractor shall agree with the Engineer the amount
of time required by the Engineer to consider and comment on the designs and/or drawings. The same time frame requirements will apply to any
resubmissions of the designs and/or drawings that may be required.
A1.2.4.3 Performance based systems

The specifications pertaining to the provision and implementation of performance based systems are given in Part D of the various Sections of
each of the Chapters of this Standard Specification where applicable.
A1.2.5 MATERIALS
A1.2.5.1 General
The Contractor shall confirm the quantities of all manufactured items or materials required for the completion of the Works with the Engineer
before finalizing any orders or production processes.
The Contractor, before using manufactured articles or materials that are required to comply with any specification, shall furnish the Engineer
with certificates showing that the materials do comply with that specification. Where so specified, materials shall bear the official mark of the
appropriate authority. All materials and products which should comply with a South African National Standard Specification (SANS) shall carry
the certification mark of a SANAS accredited certification body.
Samples ordered or specified for inspection, comment and/or approval by the Engineer prior to the manufactured articles or materials being
ordered, procured or used in the Works shall be delivered to the Engineer's site office at least seven calendar days, or such longer period that
may be specified in the Contract Documentation, before such comment or approval is required.
Unless otherwise specified, all proprietary materials shall be used and placed in strict accordance with the relevant manufacturer's current
published instructions. Agrément certified products shall be used and placed in accordance with their Agrément certification criteria.
All manufactured articles or materials supplied by the Contractor for the permanent Works shall be new and unused unless stated otherwise in
the Contract Documentation. Manufactured articles and materials to be included in the Works shall not be damaged in any way and, should they
be damaged during manufacture, delivery or by the Contractor during handling, transportation, storage, installation or testing they shall be
replaced, or repaired to comply with the original specification, by the Contractor at his own cost.
All places where articles and materials are being manufactured or obtained for use in the Works, and all the processes in their entirety
connected therewith, shall be open to inspection by the Engineer (or other persons authorised by the Engineer) at all reasonable times.

A1.2.5.2 Mix designs
Unless otherwise specified in the Contract Documentation, the Contractor shall be responsible for the design of all material mixes. The
Contractor shall make allowance for the material mix design approval process in the Contractor’s programme. Before commencing with the
associated construction activities, the Contractor shall be responsible for the following procedures in connection with the design of material
mixes:
• Sampling and testing of construction materials to determine their properties and suitability for use in materials mixes and in the Works,
all according to relevant standard methods and procedures.
• Production of the required mix designs - in conjunction with the Engineer if required.
• Production of laboratory, production/plant and/or trial mixes.
• Adjustments to the mix designs and reproduction of the required laboratory, production/plant and/or trial mixes.
• Construction and testing of trial sections and/or other trials as required.
• Submission of duplicate samples and the proposed mix designs to the Engineer for review and comment, and approval if so specified in
the Contract Documentation.
• Verification of the mix designs, trials and/or trial sections before commencing with the permanent Works.
The Contractor’s mix designs shall be submitted to the Engineer using the Employer’s standard forms where they are provided, or in any other
format which includes all the relevant information and which is acceptable to the Engineer.
A1.2.6 CONSTRUCTION VEHICLES AND EQUIPMENT

The Contractor shall submit a list of the construction vehicles and equipment to be used on the site of the Works to the Engineer for review
before the commencement of the Works.
The Contractor shall ensure that all construction vehicles and equipment used on the site of the Works and on public roads shall comply with all
current legislation and regulations.
The Contractor shall also ensure that all construction vehicles and any equipment that may travel on roads used by the public are:
• Suitable for their intended purpose.
• Maintained in good working order.
• Inspected daily by the operator or driver - the inspection records shall be kept in the vehicle or item of equipment.
• Equipped with the following:
− A flashing amber LED light / light bar of an approved design. The flashing light / light bar shall be mounted so that it is clearly visible
in daylight from all directions. They shall be switched on continuously while the vehicles are on site, are manoeuvring in or out of
traffic or are travelling or parked alongside roads open to public traffic.
− A warning sign with the wording CONSTRUCTION VEHICLE in retro-reflective Class 3 red letters at least 200mm high on a retro-
reflective Class 3 white background which shall be mounted in a visible position at the rear of every vehicle or any item of
construction plant which may travel on roads used by the public.
− An automatic acoustic reversing alarm.
The Contractor shall confirm to the Engineer in writing that all the construction vehicles and mobile equipment to be used on the site of the
Works comply with all the legal and other specified requirements before any vehicles and construction equipment will be permitted to commence
operating on the site of the Works.

A1.2.7.1 Programme of work
a) General
This Clause describes the requirements for the preparation, submittal, update and revision of the Contractor's programme. These requirements
are in addition to, or expand upon, the requirements for programming the Works which are given in the Conditions of Contract or elsewhere in
The Contractor's programme shall be used by the Contractor to plan and execute the Works. The programme will also be used by the Engineer
to monitor progress and it may be used as the basis for the assessment of extensions of time and the effect of any delays on the progress of the
Works.
The Contractor’s original baseline programme shall be reviewed and updated monthly, or as required in the Contract Documentation, to ensure
that the programme always reflects the actual progress of the Works.
Scheduling of work and monitoring of progress can be done to various degrees. Extensive scheduling has its benefits in controlling progress
and in the evaluation of delay claims, but the amount of effort involved in this can be considerable and may not be required on all contracts,
especially on relatively small Works. This specification makes provision for two schemes: Scheme 1 where the programme may be kept
relatively simple, and Scheme 2 with more extensive requirements for complex or high value projects.
Whether a Scheme 1 or Scheme 2 programme is required will be indicated in the Contract Documentation. Scheme 1 will apply if nothing is
indicated in the Contract Documentation. If only a Scheme 1 programme is indicated the Contractor shall still be able to incorporate some or all
the requirements applicable to Scheme 2 in the programme if he so wishes.

b) Scheme 1
The Contractor’s programme shall be in the form of a bar chart with logic links identifying critical activities forming the critical path. The
Contractor is encouraged to prepare the programme using scheduling software but this is not a requirement.
All significant activities must be reflected on the programme. The degree to which these activities are broken down into sub-activities is left to
the discretion of the Contractor, but it is pointed out that too little detail will impact on the degree to which the programme can be used to
manage time on the project, and to assess the impact of any delays.
The equipment and labour resources which are compatible with the planned rates of production and activity durations should be allocated to all
the major programmed activities.
c) Scheme 2
The initial / first programme to be submitted by the Contractor at the start of the contract, within the time limits specified in the Contract
Documentation, shall include all the activities required for at least the first three months of work in detail, and need only show the major activities
for the balance of the work. The Engineer will then comment on the Contractor’s initial programme and the Contractor shall revise the
programme if necessary.
Within six weeks of the commencement of the Works on site the Contractor shall submit a full programme which covers all the activities required
to complete the full Works in the necessary detail (unless the initial programme already included all the work in detail). The Engineer will then
comment on the Contractor’s full programme and the Contractor shall revise the programme if necessary.
The initial and full programmes should be drawn up using the software specified in the Contract Documentation. If no such software is specified,
the Contractor should use generally acceptable software intended for the creation of network diagrams and linked bar charts, and which can
produce the schedules which may be required in the Contract Documentation. If required, a licenced copy of such software should be provided
to the Engineer for the duration of the contract.
The full programme shall make provision for and show at least the following:
• Logic links identifying critical activities forming the critical path.
• The activities in all work packages including those by the Contractor’s sub-contractors and suppliers, service owners, any sub-
contractors and suppliers directly employed by the Employer and others.
• The equipment resources required for each activity and which are compatible with the planned rate of production.
• The labour resources required for each activity and which are compatible with the planned rate of production.
• The earliest and latest start and finish dates for every activity in each work package. Activities shall include all scope activities and any
activities or time durations expected in addition to scope activities.
• Access dates required or each phase or section of the Works.
• The earliest and latest start and finish dates for each phase or section of the Works, including dates when the Contractor plans to
complete work to allow any other sub-contractors, suppliers or service owners the necessary access to do their work.
• Programme milestones and other key dates.
• Allowances for rain delays, holiday periods and the Contractor’s pay weekends.
• Dates by which designs and drawings for the temporary and permanent Works and the mix designs which are to be produced by the
Contractor will be submitted to the Engineer for comment and dates by which comments on such design work, drawings and mix
designs from the Engineer will be required by the Contractor, allowing time for submittals, re-submittals and reviews.
• Dates by which samples of manufactured articles or materials to be produced by the Contractor will be submitted for approval by the
Engineer and dates by which approval of such samples will be required by the Contractor, allowing time for submittals, re-submittals and
reviews.
• Procurement periods and delivery dates for the major items of plant and materials to be incorporated into the Works.;
• Occupation dates and re-commissioning dates of utilities and services affected by the Works.
• Dates by which major work items will be ready for testing by the Engineer or the Employer.
• Details and dates of any information required from the Engineer or the Employer.
• The work contained in all defined provisional sums.
• Activities representing the likely work content of undefined provisional sums, complete with logic links but with durations set to zero
(unless specified otherwise or until the scope of the work is defined).
• Commissioning periods.
• Provisions for float, time risk allowances, quality control procedures, health and safety requirements and any other requirements that
may be set out in the Contract Documentation.
The main activities, and all activities where any delay is likely to lead to a delay in the completion of the Works, shall be resourced. The
resourcing input should contain details of the Contractor's resource requirements in terms of manpower, gang sizes, tradesmen, production
rates, items of construction equipment and materials and quantities of work allowed for in sufficient detail to explain the Contractor's assumed
rates of production and activity durations.
Details of schedules to be provided with the programme may be stipulated in the Contract Documentation. Typical schedules that may be
requested include, inter alia, equipment and labour resource deployment schedules, cash flow schedules and schedules of critical activities.
d) Updating and revising the programme
The Contractor shall submit an updated programme at the end of every month which indicates the current status of the Works. The Contractor
shall show the updated programmed completion date on this updated programme, compared with the completion date on the previous update.

When using a Scheme 2 programme the Contractor shall provide with each monthly programme update a schedule that compares the current
float values on all key activities with the float values on corresponding items on the programme of the previous month. Brief reasons for
substantial deviations should be provided on the schedule. The Contractor shall also submit a written report giving more detail for differences in
progress and describing what actions will be taken to make up for any lost time.
The Contractor shall revise the programme when instructed to do so by the Engineer in accordance with the requirements of the Conditions of
Contract or when the Contractor is aware that the programme no longer reflects the way in which the Contractor plans to execute the remaining
work. Failure to do so will compromise the extent to which the programme may be used to evaluate any delays and any extension of time that
may be due.
The revised programme shall introduce changes to the production rates if the production rates being achieved on site differ notably from the
programmed production rates. The revised programme should reflect any actions, and any changes to the equipment and labour resources, that
the Contractor intends to implement to address slippage on the programme. Such actions could include the provision of additional resources, a
change in the sequence of work, a change to the work methods, etc.
A1.2.7.2 Setting out of the Works and the protection of beacons

The Contractor shall check the condition of all reference and level beacons provided and shall satisfy himself that they have not been displaced
and that they are all correct with respect to both their position and level. If beacons have been destroyed, displaced or damaged before the site
is handed over to the Contractor, the Engineer will arrange to have new beacons installed, unless such beacons are declared non-essential. A
beacon which has been displaced shall not be used unless its true position and level have been re-established and the new values verified by
the Engineer.
The Contractor shall take care that property beacons, trigonometrical survey beacons or setting-out beacons are not displaced or destroyed
without the consent of the Engineer. Property beacons and trigonometrical survey beacons that have been displaced or destroyed during
construction activities shall be replaced by a registered land surveyor, who shall certify such replacement, all at the Contractor’s cost.
In cases where the displacement of or damage to property beacons or trigonometrical-survey beacons is unavoidable, the Contractor shall notify
the Engineer in good time so that he may arrange to have such beacons suitably referenced and reinstated.
Where a beacon is likely to be displaced during construction operations, the Contractor shall establish suitable reference beacons at locations
where they will not be displaced during construction. No beacon shall be covered over, displaced or destroyed before accurate reference
beacons have been established and details of the position and levels of such beacons have been submitted to and accepted by the Engineer.
The Contractor's reference beacons shall be of an acceptable quality and durability sufficient to ensure that they remain in the correct position
and level for the duration of the work for which they are required.
To ensure beyond all doubt that the complex elements of the road, such as traffic interchanges, structures and other important features are
located correctly, the Contractor shall check all setting-out by a second method. The Engineer may at any time request the Contractor to submit
proof that his setting-out has been satisfactorily carried out and checked.
To protect beacons, the boundary fences of the road reserve shall be splayed at corners to avoid the use of corner posts in the same position as
property or trigonometrical survey beacons.
Accurate control of line and level shall be provided by the Contractor at all stages of construction. In respect of the road itself, control shall be
provided at 20 m intervals or at such closer intervals as may be required by the Contractor to meet the specified tolerances or as may be
directed by the Engineer for horizontal and vertical curves. Wherever necessary, but particularly on completion of the fill and the base layer, the
Contractor shall re-establish stake-line pegs at sufficiently close intervals to determine accurately the position of the edges of the base layer,
surfacing and any kerbing, guardrails, road markings and other road elements that must be accurately placed.
The checking of any surveys, setting out, lines or levels by the Engineer shall not relieve the Contractor of his responsibility for the correct
survey and setting out and for the construction of the Works to the lines and levels specified in the Contract Documentation.
A1.2.7.3 Services
The specifications relating to the location, identification, protection of and/or moving and reinstating of existing services that may be affected by
the construction of the Works are given in Clause A2.1.3.2 b), c) & d) of Chapter 2.
A1.2.7.4 Work on, over, under or adjacent to utilities

All work carried out on, over, under or adjacent to utilities shall be carried out strictly in accordance with the latest edition of the official
specifications of the utility owner, a copy of which will normally be included in the Contract Documentation. Where no such copy is included in
the Contract Documentation, or where the copy included in the Contract Documentation is amended or superseded by another, the Contractor
shall obtain the latest edition from the utility owner, which shall be kept on the site, before any work of this nature is commenced.
The Contractor’s attention is drawn particularly to the requirements contained in the Contract Documentation, or provided by the statutory
authority, regarding the approval that must be obtained from the utility owner for:
• Issuing a work permit.
• Allowing occupation of its property.
• All particulars of programmed activities during such occupation.
• Approval of the Contractor’s work and/or construction methods.
• The design and/or specifications of any temporary Works that may be required.
• All measures required to protect the utilities that may be affected by the construction of the Works.
A1.2.7.5 Use of explosives – compliance with legislation and regulations

The Contractor shall ensure that he complies fully with all current legislation and regulations pertaining to the manufacture, purchasing,
transport, storage and use of explosives, including:
• The latest version of the Explosives Regulations R 1604 dated 08h September 1972 issued under the Explosives Act (Act No. 26 of
1956 as amended in R 2371 dated 14th December 1973 and in any further subsequent amendments that have been issued up until the
start date of the Contract.

• The latest version of the Explosives Regulations R 109 dated 17th January 2003 issued under Section 43 of the Occupational Health
and Safety Act (Act No. 85 of 1993) as amended in any amendments that have been issued up until the start date of the Contract.
• The latest version of the Explosives Act No. 15 of 2003 and as amended in any amendments that have been issued up until the start
date of the Contract.
• The latest versions of all other applicable national, provincial or municipal legislation, regulations and by-laws.
Specifications for blasting shall be in accordance with the requirements in Section A12.10 of Chapter 12.
A1.2.8 WORKMANSHIP
The quality of the workmanship, products, elements and goods provided by the Contractor shall be controlled by a process control system
executed by the Contractor as well as by a system of acceptance control executed by the Employer, the Engineer or any other appointed agent
as specified below. This quality assurance process, including the liability for the payment of the testing required, is specified in Chapter 20 of
this Standard Specification.
A1.2.8.1 Process quality control

The onus rests with the Contractor to produce work and products which comply with the characteristics and requirements of the specifications
and drawings in all respects. The Contractor shall institute a quality management system and provide experienced engineers, technicians,
foremen, inspectors and other technical staff, under the control of a designated quality manager, to give effect to and manage the quality
management system.
Where any performance based specifications apply, the Contractor shall institute a quality management system that will ensure and
demonstrate that the required performance standards have been met and, where applicable, will continue to be met for any period which has
been specified in the Contract Documentation.
The quality management system shall outline the minimum requirements and actions to be taken during the construction of all elements of the
Works and shall include monitoring of the various properties of the elements of the Works using either a fully ISO certified quality assurance
system or an appropriate quality management system based on recognised sampling and testing principles.
For continuous concrete and asphalt production using mixing plants the Contractor shall augment the quality management system by the use of
appropriate automated equipment capable of producing continuous measurements and data printouts for the relevant mix parameters such as
mass of mix components, production and storage temperatures, moisture contents etc. during the mixing / production process. All the
measurement information shall be kept for the duration of the Contract and the Defects Notification Period and it shall be made available to the
Engineer when requested.
The Contractor shall carry out testing and measurement in accordance with the requirements specified in the Contractor’s quality management
system to confirm the conformance of the Works with all the relevant requirements and specifications.
Although it is not a requirement for the Contractor to conduct regular tests and measurements on commercially produced products bearing the
SANS, or any other internationally recognised, specification for products such as cement, road-lime, paint, bitumen, steel pipes, sealants and
bridge bearings etc. the quality of such materials and products shall nevertheless be checked on a regular basis in liaison with the Engineer.
The costs for any such sampling, tests and measurements shall be borne by the Employer in the event of compliance with the requirements and
specifications. In the event of non-compliance with the requirements and specifications the costs for any such sampling, tests and
measurements and subsequent corrective or remedial actions shall be borne by the Contractor.
All measurements and test results shall be submitted, without delay, to the Engineer on the completion of each element of the Works. Should
the sampling, testing and measurements for any end product be carried out by the accredited combined laboratory, or any other accredited
laboratory or institution, and prove compliance with the specifications, the Engineer may accept these results for acceptance control purposes at
the cost of the Employer.
In the event of method specifications being applicable for the construction of certain layers, products or elements, the Contractor shall follow the
proposed methodology given in a method statement that has been commented on and/or accepted by the Engineer. Where applicable the
methodology to be used and the acceptability of the work / product shall be demonstrated by means of an appropriate trial section carried out by
the Contractor. Any subsequent deviation from the proposed methodology shall be submitted to the Engineer for comment prior to
implementation.
All completed elements of the Works shall be submitted to the Engineer for written acceptance and the Contractor shall not cover up any
completed work prior to such acceptance being issued. The Contractor shall plan, and make arrangements for, the submission of work for
acceptance control in a manner which will afford the Engineer a reasonable and timeous opportunity for inspection, testing and measurement of
the Works.
The Contactor shall agree all the process control sampling, testing, measurement and approval processes with the Engineer for each element of
the Works before commencing work. Regardless of the acceptance of any materials or products based on the Contractor’s process control the
Contractor shall remain fully responsible for any defective material, product or plant/equipment used in the temporary and permanent Works.
A1.2.8.2 Acceptance quality control

Acceptance quality control shall be conducted by the Employer and/or the Engineer and it shall consist of visual inspections, sampling, testing
and measurements in terms of the methods and procedures specified in Chapter 20 of this Standard Specification and/or in the Contract
Documentation in order to ensure that the Contractor complies with all his obligations prior to the acceptance of and payment for the Works.
The properties, characteristics and workmanship for each product or completed element of the Works shall be assessed for acceptance as
specified in Chapter 20. Other properties, characteristics and requirements not prescribed in Chapter 20 shall be assessed and judged in terms
of the specified requirements, permissible deviations and tolerances specified in the other chapters.
In the event of elements constructed using method specifications, the Engineer shall regularly monitor and inspect the process visually and
ensure that the work is constructed in accordance with the approved method statement as well as with any applicable industry norms, standards
and best practices. The Engineer may, however, request any sampling, tests and measurements of the final product to ensure conformance to
the design requirements. The costs for any such sampling, tests and measurements shall be borne by the Employer in the event of compliance
with the requirements and specifications. In the event of non-compliance with the requirements and specifications the costs for any such tests
shall be borne by the Contractor.

Regardless of the Employer’s quality control acceptance of any materials or products the Contractor shall remain fully responsible for any
defective material, product or plant/equipment used in the temporary and permanent Works.

B1.2 GENERAL REQUIREMENTS AND PROVISIONS
CONTENTS
B1.2.1 SCOPE
B1.2.2 DEFINITIONS
B1.2.3 GENERAL
B1.2.5 MATERIALS
B1.2.8 WORKMANSHIP
B1.2.1 SCOPE
Any requirements for the labour enhancement of some of the work activities will be stated in the Contract Documentation.
The Contractor shall indicate how these specified requirements will be met in his Works programme.
B1.2.2 DEFINITIONS
Definitions as provided in Clause A1.2.2 shall also apply.
B1.2.3 GENERAL
Any activity specified in PART A, where hand work is given as an alternative, shall be executed in such a way as to maximise labour.
B1.2.4 DESIGN BY CONTRACTOR/PERFORMANCE BASED SYSTEMS

Not required for Section A1.2.
B1.2.5 MATERIALS
The provisions of Part A shall apply.

Where reference is made in Part A to appropriate equipment, the use of light/hand operated equipment shall be evaluated during trial sections.
The specifications in Part A shall be equally applicable.

As specified in Clause A1.2.7.1.1b) the labour force shall be allocated as a resource to each of the major activities shown in the Contractor’s
programme when a Scheme 1 programme is specified.
As specified in Clause A1.2.7.1.1c) the labour force shall be allocated as a resource to each of the activities shown in the Contractor’s Works
programme when a Scheme 2 programme is specified.
B1.2.8 WORKMANSHIP

C1.2 GENERAL REQUIREMENTS AND PROVISIONS
(i) Preamble
The tendered rate for each item shall include full compensation for providing, operating, maintaining and decommissioning upon completion, of
all the construction equipment, labour, tools, incidentals and supervision to carry out the activity or construct the works in the item, unless
otherwise stated.
Any prime cost or provisional sums shall be paid in accordance with the provisions of the Conditions of Contract. The charge or mark-up
tendered or allowed for is a percentage of the amount actually paid under the prime cost or provisional sum. This percentage shall cover all the
Contractor’s handling, supervision, profit and liability costs to provide the services in the prime cost or provisional sum item.
(ii) Items that will not be measured separately
The following required activities will not be measured or paid for separately and the Contractor shall include the cost thereof in other items as
deemed appropriate:
1. Cleaning and removal to spoil of all spilt construction materials off public or privately owned roads which are used as haul roads, access
roads and detours or trafficked areas which are adjacent to the construction area when partial or half width construction is carried out.
2. Compliance with the requirements related to the Contractor’s activities on properties outside the road reserve.
3. Carrying out any remedial work required to defective or rejected work.
4. Attendance at site meetings.
5. The provision, transport and application of construction water.
6. All work in restricted areas unless provided for in the Contract Documentation.
7. The design of any permanent work that may be specified to be designed by the Contractor in the Contract Documentation.
8. The design and construction of all temporary work.
9. The preparation and submission of design calculations and drawings for temporary and permanent work designed by the Contractor.
10. Setting out of the Works and the protection of beacons.
11. Obtaining any outstanding permits required to comply with the requirements of the EA, the EMP and the WULs that were not obtained by
the Employer and included with the Contract Documentation.
12. Compliance with the requirements relating to work on, over, under or adjacent to utilities.
13. The Contractor’s process control testing.
(iii) Items to be measured and paid for using items specified elsewhere in the specifications
For activities in Table C1.2-1 payment items specified in other Chapters or Sections of the specifications, where they relate to work under this
Section, will be listed in the Pricing Schedule.
Table C1.2-1: Payment items from other Chapters or Sections
Activity Section 1.2 reference Section item reference
Provision and later removal of the contract sign boards. A1.2.3.12 C1.3.2 of Chapter 1
Provision of all site security measures for the Contractor’s
facilities and equipment and at the Site of the Works,
A1.2.3.17 C1.3.1 of Chapter 1
quarries, borrow pits and traffic accommodation facilities and
equipment.
Provision of security at the engineer’s offices, laboratories, A1.2.3.17 C1.4.8 of Chapter 1
and site and rented accommodation.
Obtaining construction/work permits from service authorities A1.2.3.22b) C2.1.3 of Chapter 2
Identification, protection and relocation of existing services A1.2.7.3 C2.1.1 & C2.1.2 of Chapter 2
Acceptance quality control – sampling and testing requested
A1.2.8.2 C20.1.2.2 of Chapter 20
by the Engineer
(iv) Items specifically for this Section of the specifications
Item Description Unit

C1.2.1 Environmental Management
C1.2.1.1 Monitoring of compliance with and reporting on the EMP month
C1.2.1.2 Dedicated environmental officer (if specified in the Contract Documentation) month
The unit of measurement for item C1.2.1.1 is the month or part thereof that the service is required and provided during the approved
contract period. The contract rate shall include full compensation for the regular monitoring of compliance with and reporting on the
EMP in accordance with the specified requirements.

The unit of measurement for item C1.2.1.2 is the month or part thereof that the service is provided during the approved contract
period. The contract rate shall include full compensation for the provision of a dedicated environmental officer including all
employment costs, accommodation and transport costs and all other associated overhead costs.

C1.2.2 Programming and Reporting
C1.2.2.1 Submission of a Scheme 1 Programme lump sum
C1.2.2.2 Reviewing and updating a Scheme 1 Programme month
C1.2.2.3 Submission of a Scheme 2 Initial Programme lump sum
C1.2.2.4 Submission of a Scheme 2 Full Programme lump sum
C1.2.2.5 Reviewing and updating a Scheme 2 programme every month month
C1.2.2.6 Preparation and submission of all information and reports specified in the Contract month
Documentation
The unit of measurement for item C1.2.2.1 shall be the lump sum. The lump sum shall include full compensation for preparing and
submitting a Scheme 1 Programme, including providing software and tutorials to the Engineer if required.
The unit of measurement for item C1.2.2.2 shall be the month or part thereof that the service is provided during the approved contract
period. The monthly rate shall include full compensation for reviewing and updating the Scheme 1 Programme as required and for
submitting a copy of the current programme to the Engineer at the end of each month.
submitting a Scheme 2 Initial Programme, including providing software and tutorials to the Engineer if required
submitting a Scheme 2 Full Programme.
period. The monthly rate shall include full compensation for reviewing and updating the Scheme 2 Initial and Full Programmes as
specified in the Contract Documentation and for submitting of a copy of the current programme to the Engineer at the end of each
month.
period. The monthly rate shall include full compensation for collecting and reporting on all data and information specified in the
Contract Documentation and for submitting it to the Engineer at the specified times.

C1.2.3 Routine road maintenance of existing public roads within the Site of the Works or
other public roads outside the Site of the Works which are used as detours
C1.2.3.1 Grass cutting hectare (ha)
C1.2.3.2 Drain cleaning kilometre (km)
C1.2.3.3 Cleaning out culverts cubic metre (m3)
C1.2.3.4 Collection of rubbish / litter kilometre (km)
C1.2.3.5 Base patching using crushed stone material stabilised with bitumen emulsion and cement cubic metre (m3)
C1.2.3.6 Base and/or surface patching using cold premixed asphalt kilogram (kg)
C1.2.3.7 Base and/or surface patching using hot plant mixed asphalt ton (t)
C1.2.3.8 Replacement of damaged guardrails including posts metre (m)
C1.2.3.9 Grading of temporary gravel deviations and existing roads used as detours kilometre (km)
C1.2.3.10 Watering of temporary gravel deviations and existing roads used as detours kilolitre (kl)
C1.2.3.11 Other road maintenance work ordered by the Engineer provisional sum
C1.2.3.12 Handling cost, profit and all other charges in respect of item C1.2.3.11 percentage (%)
C1.2.3.13 Liaison with the routine road maintenance contractor month
Payment will only be made under items C1.2.3.1 to C1.2.3.13 when the relevant item of routine maintenance work has been ordered
by the Engineer in writing and the Engineer has confirmed in writing the scope, quantity and/or frequency of work that is to be carried
out.
The unit of measurement for item C1.2.3.1 shall be the hectare. The contract rate shall include full compensation for cutting and
removing grass in restricted and steep access areas with hand tools in addition to mowing and removing grass in more accessible
areas.

The unit of measurement for items C1.2.3.2 shall be the kilometre of side or median drain cleaned. Each drain shall be measured
separately. The contract rate shall include full compensation for the removal of all silt, mud, gravel, rocks and any other obstructions
in the drain as well as for loading and hauling the removed material to spoil regardless of the haul distance.
The unit of measurement for item C1.2.3.3 shall be the cubic metre. The contract rate shall include full compensation for the removal
of all silt, mud, gravel, rocks and any other obstructions from inside the culvert or from the culvert entrance and exit as well as for
loading and hauling the removed material to spoil regardless of the haul distance.
The unit of measurement for item C1.2.3.4 shall be the kilometre measured along the centreline of the road or along the median of a
dual carriageway road. The contract rate shall include full compensation for collecting all the rubbish / litter within the road reserve
boundary and carting it to an approved disposal site regardless of the haul distance.
The unit of measurement for items C1.2.3.5, C1.2.3.6 and C1.2.3.7 shall be the cubic metre, kilogramme and tonne respectively. The
contract rates shall include full compensation for excavating the failed area of the road to the depth indicated by the Engineer,
cleaning out and squaring off the excavation, priming the compacted crushed stone surface or the floor and sides of the excavation
as applicable and then backfilling the excavation as specified in the Contract Documentation. The contract rates shall also include full
compensation for all final site cleaning and removal to spoil of all surplus regardless of the haul distance.
The unit of measurement for item C1.2.3.8 shall be the linear metre of guardrail replaced. The contract rate shall include full
compensation for removing the damaged guardrails and posts to spoil or storage as specified by the Engineer, reinstating or
replacing any displaced or damaged guardrail posts and providing and installing a new guardrail in the correct position.
The unit of measurement for item C1.2.3.9 shall be the kilometre of temporary gravel deviation, or existing gravel road used as a
detour, which is graded smooth with a motor grading to remove all corrugations and to redistribute the bladed gravel material evenly
across the road surface as and when instructed by the Engineer in writing. The contract rate per kilometre shall include full
compensation for providing and maintaining the motor grader and grading the road surface to restore the riding quality as specified in
the Contract Documentation, regardless of any variations in the width of roadway being graded.
The unit of measurement for item C1.2.3.10 shall be the kilolitre of water sprayed on the surface of the existing temporary gravel
deviation or existing gravel road being used as a detour as and when instructed by the Engineer in writing. The contract rate shall
include full compensation for providing, transporting and spraying the water on the road surface.
The provisional sum allowed under item C1.2.3.11 shall provide for all other routine road maintenance work carried out by the
Contractor that may be required as specified in the Contract Documentation or as ordered by the Engineer. The provisional sum shall
be paid in accordance with the provisions of the Contract Documentation. Where applicable existing contract rates or accepted day
work rates will be used.
The percentage under item C1.2.3.12 is a percentage of the amount spent under item C1.2.3.11 which shall include full
compensation for all handling costs, profit and all other charges in connection with arranging and carrying out the maintenance work.
The unit of measurement for item C1.2.3.13 shall be the month or part thereof that the service is provided during the approved
contract period. The contract rate shall include full compensation for all the Contractor’s activities, meetings and correspondence
related to liaising with and accommodating the activities of the Employer’s routine road maintenance contractor. Payment under this
item will only be applicable if some of or all of the routine maintenance work is carried out by a separate contractor appointed by the
Employer.

C1.2.4 Stakeholder liaison month
The unit of measurement for item C1.2.4 shall be the month or part thereof that the service is provided during the approved contract
period. Part of a month shall be calculated to two decimal places. The contract rate shall include full compensation for all on-going
stakeholder liaison that the Contractor is required to carry out after the contract has been awarded as specified in Section A1.2,
Clause A1.2.3.18, including informing stakeholders of the Works procedures and of the accommodation arrangements for
pedestrians and non-motorised traffic through or over the site of the Works, providing health and safety information to stakeholders,
arranging and attending meetings, providing meeting facilities and sandwiches, tea, coffee or soft drinks. Payment of the monthly
sum shall be made every month for the duration of the approved contract period regardless of the amount of stakeholder liaison
required during that month.

C1.2.5 Safety
C1.2.5.1 Health and safety plan lump sum
C1.2.5.2 Implementation of health and safety plan month
The unit of measurement for item C1.2.5.1 shall be the lump sum. The lump sum shall include full compensation for assessing the
risks associated with the Works, reviewing and taking cognisance of the Employer’s health and safety specifications and/or
requirements, preparing the Contractor’s health and safety plan and for the submission of a copy of the plan to the Engineer.
The unit of measurement for item C1.2.5.2 shall be the month, or part thereof for the duration of the approved contract period. Part of
a month shall be calculated to two decimal places. The contract rate shall include full compensation for implementing the health and
safety plan, including the provision of a dedicated, full time health and safety officer, carrying out all the required site health and
safety training and briefings, staff medical evaluations, monitoring and administrating the health and safety plan and for supplying all
transport, personal protection safety items, other health and safety equipment, safety notices and any other health and safety related
items that are required on site. The contact rate shall also include the provision of a monthly health and safety compliance report to
the Engineer.

C1.2.6 Work adjacent to properties
C1.2.6.1 Survey of adjacent properties number (No.)

C1.2.6.2 Preventive and/or mitigation measures provisional sum
The unit of measurement for item C1.2.6.1 shall be the number of properties adjacent to the Works that need to be surveyed, as
agreed in advance with the Engineer. The contract rate shall include full compensation for carrying out all the requirements given in
clause A1.2.3.13.
The provisional sum allowed under item C1.2.6.2 shall provide for all additional preventive and/or mitigation measures required that
are approved by the Engineer as being necessary after the Contractor has implemented all other reasonable measures to avoid
and/or reduce the damaging effects relating to carrying out the Works adjacent to properties. The amount payable to the Contractor
shall be calculated in accordance with the requirements given in the Contract Documentation or agreed to by the Engineer.
The percentage under item C1.2.6.3 is a percentage of the amount spent under item C1.2.6.2 which shall include full compensation
for all handling costs, profit and all other charges in connection with arranging and carrying out the agreed preventive and/or
mitigation measures.

C1.2.7 Road safety audits
C1.2.7.1 Stage 4 work zone traffic management audit provisional sum
C1.2.7.3 Stage 5 pre-opening stage traffic safety audit provisional sum
The provisional sum allowed under item C1.2.7.1 shall be used to pay the actual cost of appointing an independent auditor and
carrying out a Stage 4 work zone traffic management audit as prescribed in the SARSAM and in Clause A1.2.3.20 a) and for
preparing the audit report and submitting two copies of the report to the Employer and the Engineer.
for all handling costs, profit and all other charges in connection with arranging and carrying out the specified audit.
The provisional sum allowed under item C1.2.7.3 shall be used to pay the actual cost of appointing an independent auditor and
carrying out a Stage 5 pre-opening stage traffic safety audit as prescribed in the SARSAM and in Clause A1.2.3.20 b) and for
preparing the audit report and submitting two copies of the report to the Employer and the Engineer.
for all handling costs, profit and all other charges in connection with arranging and carrying out the specified audit.

C1.2.8 Dayworks
C1.2.8.1 Personnel
(a) Unskilled labourer hour
(b) Semi-skilled labourer hour
(c) Skilled labourer hour
(d) Gang leader hour
(e) Foreman hour
(f) Skilled Artisan hour
C1.2.8.2 Construction equipment (specify size and/or model number) hour
(a) Motor grader hour
(b) Vibratory roller hour
(c) Pneumatic roller hour
(d) Front end loader hour
(e) Tractor loader backhoe hour
(f) Excavator hour
(g) Compressor hour
(h) Other equipment (specify) hour
C1.2.8.3 Vehicles (specify size)
(a) Light delivery vehicle km
(b) Flatbed truck km

(c) Dump truck km
(d) Other vehicles (specify) km
C1.2.8.4 Materials
(a) Procurement of materials provisional sum
(b) Contractor's handling costs, profit and all other charges in respect of item C1.2.8.4(a) percentage (%)
The unit of measurement for items C1.2.8.1(a) to C1.2.8.1(f) shall be the hour that the personnel are engaged on the work inclusive
of transport to and from the site. Non-working hours for meal breaks, rest periods, transport breakdowns, lack of construction
equipment or materials or any other reason shall not be measured. The contract rates shall include full compensation for all overhead
charges and profit, leave pay, bonuses, subsistence, allowances, Employer's contributions, additional payment for overtime where
applicable, insurances, housing, site supervision, provision and use of small hand tools and appliances, non-mechanical plant and
equipment and consumable stores as well as for all administrative, supervisory, operative and contingent costs related to the supply
of personnel.
The unit of measurement for items C1.2.8.2(a) to C1.2.8.2(g) shall be the hour that the construction equipment is engaged on the
work inclusive of transport to and from the site. Non-working hours for operator meal breaks and rest periods, equipment breakdowns
and maintenance, lack of materials or any other idle time or reason shall not be measured. The contract rates shall be an all-inclusive
hire charge for the use of the construction equipment and operator and shall include full compensation for all administrative,
supervisory, fuel, maintenance, operational, transportation, depreciation and any other contingent costs and profit relating to the
operation of the construction equipment. The contract rates shall be based on the type and size of equipment that the Contractor
intends to provide for the construction of the main Works.
The unit of measurement for items C1.2.8.3(a) to C1.2.8.3(d) shall be the kilometre travelled by the vehicle while engaged on the
dayworks. The contract rates for shall be an all-inclusive hire charge for the use of the vehicle, the driver and the driver’s assistant/s if
required. The contract rates shall also include full compensation for all administrative, supervisory, fuel, maintenance, operational,
transportation, depreciation and any other contingent costs and profit relating to the operation of the vehicle.
The provisional sum allowed under item C1.2.8.4(a) shall include full compensation for the cost of all materials (excluding value
added tax) that are required for the dayworks as ordered by the Engineer. The provisional sum shall be paid in accordance with the
provisions of the Contract Documentation.
The percentage under item C1.2.8.4(b) is a percentage of the amount spent under item C1.2.8.4(a) which shall include full
compensation for all handling costs, profit and all other charges for ordering, providing, transporting and handling the materials.

C1.2.9 Disposal of non-useable assets
C1.2.9.1 Disposal of non-useable assets identified in the Contract Documentation at time of tender rate (per asset)
(list items and quantity)
C1.2.9.2 Disposal of non-useable assets not identified at time of tender provisional sum
The unit of measurement for item C1.2.9.1 shall be the lump sum tendered by the Contractor to dispose of the listed non-useable assets that
are described in the Contract Documentation and listed under this item. The rate tendered by the Contractor can be positive or negative
depending on the cost of disposing of the assets against the value that the Contractor may wish to place upon them.
The provisional sum allowed under item C1.2.9.2 shall provide for the disposal of any non-useable assets that were not already identified in the
Contract Documentation under item C1.2.9.1. The amount payable to the Contractor shall be calculated in accordance with the requirements
given in the Contract Documentation or agreed to by the Engineer. The provisional sum may be positive or negative depending on the cost of
disposing of them against the value that the Contractor may wish to place upon them.
The percentage tendered under item C1.2.9.3 is a percentage of the amount spent under item C1.2.9.2 which shall include full compensation for
all handling costs, profit and all other charges in connection with arranging and disposing of the non-useable or not required road furniture
assets. If the provisional sum agreed under item C1.2.9.2 is a negative amount, then this item C1.2.9.3 will not be applicable.

D1.2 GENERAL REQUIREMENTS AND PROVISIONS
CONTENTS
D1.2.1 SCOPE
D1.2.2 GENERAL

1.3 CONTRACTOR’S SITE ESTABLISHMENT AND GENERAL
OBLIGATIONS
CONTENTS
A1.3.1 SCOPE
A1.3.2 DEFINITIONS
A1.3.3 GENERAL
A1.3.5 MATERIALS
A1.3.8 WORKMANSHIP

A1.3 CONTRACTOR’S SITE ESTABLISHMENT AND GENERAL OBLIGATIONS

A1.3.1 SCOPE
This Section covers the establishment of the Contractor's organization, construction camps and constructional plant and their removal on
completion of the contract.
It also includes payment items to cover certain general obligations, risks and liabilities and general items of cost that are included in, but not
covered directly by the payment items in the other chapters.
A1.3.2 DEFINITIONS
Construction camps - are all areas used for erecting offices, stores, workshops, testing facilities, plant parking areas, and equipment and
material storage areas.
General Obligations - the Contractor's General Obligations shall include the following:
• Setting up, providing, insuring and maintaining the personnel, construction camps, staff accommodation, furniture, office equipment and
stationery, other temporary structures, fencing and construction equipment on the site and their removal on completion of the contract.
• Providing transport to, from and on the Site of the Works for all permanent and temporary staff and local labour, including transporting
local employees to and from their places of residence when or where necessary.
• Compliance with the requirements of the Conditions of Contract and with all the general requirements included in this Chapter 1.
• Compliance with all legislative and regulatory requirements.
• Assessing, dealing with and/or insuring all risks associated with the Contractor’s General Obligations and with the construction,
maintenance and protection of the Works.
• The protection and/or safeguarding of private property and livestock.
• The provision of security for all the Contractor’s personnel, facilities and equipment on the Site of the Works, including quarries, borrow
pits, stockpile areas and storage yards as well as for any traffic accommodation facilities and equipment that may be placed on the
approaches to, or the exit from, the Site of the Works.
• All other general obligations, overhead costs, financing charges, insurance costs and all other general items which are not specifically
included in, or covered by, this Standard Specification.
• The preparation and submission of all designs and drawings prepared by the Contractor for the temporary works or any alternative
design proposals.

A1.3.3 GENERAL
A1.3.3.1 Construction camps
The Contractor shall establish the construction camps either at the specific sites and borrow areas identified in the Contract Documentation or at
locations chosen by the Contractor. The exact location of these facilities shall be subject to the approval of the Engineer and such approval will
not be unreasonably withheld.
The Contractor shall make his own arrangements for the use of any property outside the road reserve for erection of the construction camp/s, as
well as for the provision of adequate means of access, security and the installation and supply of water, electricity and telephone services
required by the Contractor.
Before commencing with the construction of any camps the Contractor shall comply with all the requirements specified in Clauses A1.2.3.2
and/or A1.2.3.3.
If Employer-owned land can be made available for the use of the Contractor for the construction camps, the use of such land will not be treated
as a lease but will form part of the contract. In this regard the Contractor shall complete the prescribed agreement and comply with all the
conditions thereof as if it is part of the Contract. The availability of any Employer owned land will be indicated in the Contract Documentation.
On completion of the Works, all constructional plant, buildings, fencing and other temporary structures erected by the Contractor shall be
removed and the construction camp site shall be restored to its original condition and left neat and tidy. The Contractor shall also comply with all
the requirements related to the completion of the operations specified in Clause A1.2.3.2 and/or Clause A1.2.3.3.
A1.3.3.2 Housing
The Contractor shall not erect any housing or other accommodation facilities on the site in urban areas and shall make all the necessary
arrangements for accommodation of his personnel and site staff off the site, unless otherwise stated in the Contract Documentation.
The Contractor shall not erect any housing or other accommodation facilities on the site before he has obtained the written permission of the
Employer and, where applicable, the land owner and has complied fully with all applicable legislative and regulatory requirements.
A1.3.3.3 Maintenance of the Contractor’s facilities

The Contractor shall maintain the construction camps and all the Contractor’s other facilities in a clean, neat and tidy condition for the duration
of the Contract. The Contractor shall also maintain all the access roads to the Contractor’s site facilities including any publicly or privately owned
roads that the Contractor is making use of. Depending on the initial condition of the access roads this may entail repairing any potholes and
edge breaks of surfaced roads or the re-gravelling of the road and subsequently the regular watering, blading and rolling of the surface to
maintain a firm surface without excessive corrugations and loose materials. The Contractor shall ensure that the access roads to the
Contractor’s facilities are always in a safe and passable condition for normal cars under all weather conditions.
A1.3.3.4 Contractor’s own security arrangements

The Contractor shall provide all the security measures required for the Contractor’s own facilities and equipment on the Site of the Works,
including quarries, borrow pits, and for the traffic accommodation site facilities and equipment, as he deems necessary. The provision of security
measures for the duration of the Works shall be included in the Contractor’s General Obligations as defined in Clause A1.3.2.

The Contractor shall be responsible for the design of the site facilities. All applicable legislative and regulatory requirements related to building
standards and health and safety shall be complied with.
A1.3.5 MATERIALS
The Contractor shall be responsible for the selection and purchase of all materials required to construct the site facilities. All applicable
legislative and regulatory requirements with regard to building standards and health and safety shall be complied with.

Not applicable for Section A1.3.

All work required for the Contractor’s site facilities and for the Contractor’s site establishment of personnel, vehicles, plant and equipment shall
be carried out in compliance with all applicable legislative and regulatory requirements and with the requirements of the Contractor’s
environmental management and health and safety plans.
A1.3.8 WORKMANSHIP
The Contractor shall control the quality of materials and workmanship used for the construction and fitting out of the construction camps to
ensure that the applicable legislative and regulatory requirements related to building standards and to health and safety are adhered to.

B1.3 CONTRACTOR’S SITE ESTABLISHMENT AND GENERAL OBLIGATIONS
CONTENTS
B1.3.1 SCOPE
B1.3.2 DEFINITIONS
B1.3.3 GENERAL
B1.3.5 MATERIALS

B1.3.8 WORKMANSHIP
B1.3.1 SCOPE
There are no additional labour enhancement requirements for Section A1.3.
B1.3.2 DEFINITIONS

C1.3 CONTRACTOR’S SITE ESTABLISHMENT AND GENERAL OBLIGATIONS
(i) Preamble
otherwise stated.
Any prime cost or provisional sums shall be paid in accordance with the provisions of the Conditions of Contract. The charge or mark-up
There are no activities mentioned in this section that are not measured in this Section.
There are no payment related items mentioned in this Section that are measured in other Sections of the specifications.

C1.3.1 The Contractor's general obligations
C1.3.1.1 Fixed obligations lump sum
C1.3.1.2 Value-related obligations lump sum
C1.3.1.3 Time-related obligations month
The lump sums under items C1.3.1.1 and C1.3.1.2 and the contract rate per month for item C1.3.1.3 shall together include full compensation for
all the Contractor's costs, charges, overheads and profits in respect of all the Contractor's General Obligations as specified in Clause A1.3.2.
Item C1.3.1.1
The unit of measurement for item C1.3.1.1 is the lump sum. The lump sum shall include full compensation for the fixed part of the Contractor's
general obligations, i.e. that part which is substantially fixed and is not a function of the value of the Works or of the time required for the
completion of the Contract.
Payment of this lump sum will be made in three instalments, as follows:

• The first instalment, 50 % of the lump sum, will be paid after the Contractor has completed the establishment of the construction camps,
site offices, laboratories and housing, has provided the personnel, staff and equipment required to commence the Works in accordance
with all the specified requirements and has made a substantial start with construction of the Works in accordance with the approved
programme.
• The second instalment, 35 % of the lump sum, will be paid when the value of the Work done reaches one half of the Contract Amount,
excluding contingencies and price adjustments in terms of the Contract Documentation.
• The third and final instalment, 15 % of the lump sum, will be paid when the Works have been completed and taken over by the
Employer.
Item C1.3.1.2
The unit of measurement for item C1.3.1.2 is the lump sum. The lump sum shall include full compensation for that part of the Contractor's
general obligations which is a function of only the value of the Works, but not of the period of completion of the Works.
Should the final value of the Works (excluding any contract price and special material adjustment payments made in terms of the Contract
Documentation) increase or decrease in relation to the tendered contract price (less any allowances, if any, in the tendered contract price for
contract price adjustment and special material adjustment payments), the lump sum for payment item C1.3.1.2 will be increased or decreased
accordingly pro rata. The adjusted lump sum will be the full settlement of any difference in value-related general obligations resulting from an
increased or decreased value of the work.
Payment of this lump sum will be made in instalments in each payment certificate (usually issued monthly). The value of each instalment will be
in proportion to the value of Work done up to the date that the payment certificate is prepared (excluding the value of any price adjustments
made in terms of the Contract Documentation).
Item C1.3.1.3
The unit of measurement for item C1.3.1.3 is the month or part thereof that the services are provided for the approved duration of the contract.
Part of a month shall be calculated to two decimal places.
The contract rate shall include full compensation for that part of the Contractor's general obligations which are mainly a function of construction
time. The contract rate will be paid monthly, pro rata for parts of a month, from the date of commencement in terms of the Contract
Documentation until the end of the original Contract Period specified for completion of the Works.
If the original Contract Period for completion has been extended in terms of the Contract Documentation, then time-related obligations for the
extensions shall be compensated for as stipulated by the Contract Documentation.

The following conditions also apply to the time related payment made under item C1.3.1.3:
• Should the Works be certified as having been completed before the original contractual date for completion of the Works the Contractor
will then be entitled to payments of the monthly time related amount for the unexpired original Contract Period specified for completion
of the Works.
• Should the progress of the Contractor, calculated in terms of the value of the work done to date, be in arrears by more than 10 %
relative to the accepted cash flow estimate (suitably adjusted for any change in the scope of work and/or extension of time granted) then
the payments in respect of this item may be limited to a total payment to date which is in the same ratio as the actual value of Work
done relative to the estimated total value of all the Work that has to be done.

C1.3.2 Contract sign boards square metre (m2)
The unit of measurement for item C1.3.2 is the total square metre (m2) area of the approved contract sign boards (usually two) provided and
erected by the Contractor in the positions on site indicated by the Engineer. The contract rate for item C1.3.2 shall include full compensation for
all costs associated with providing, erecting and for the later removal of the contract signboards as soon as the Works have been completed.

D1.3 CONTRACTOR’S SITE ESTABLISHMENT AND GENERAL OBLIGATIONS
CONTENTS
D1.3.1 SCOPE
D1.3.2 GENERAL

1.4 FACILITIES FOR THE ENGINEER
CONTENTS
A1.4.1 SCOPE
A1.4.2 DEFINITIONS
A1.4.3 GENERAL
A1.4.5 MATERIALS
A1.4.8 WORKMANSHIP

A1.4 FACILITIES FOR THE ENGINEER

A1.4.1 SCOPE
This Section covers the provision by the Contractor of facilities for the Engineer and the Engineer’s staff. These facilities shall include the
necessary site accommodation, laboratories and offices, all the necessary furnishings and services, as well as all the arrangements in
connection with the property, buildings and/or land, on which the Engineer’s facilities will be provided.
The specifications for the site accommodation and the site laboratory and office buildings, together with all the fittings and furnishing required,
are specified in this section. If necessary, additional details and requirements will be specified in the Contract Documentation or provided by the
Engineer.
A1.4.2 DEFINITIONS
Engineer’s site facilities - the Engineer’s site accommodation, laboratories and offices are temporary buildings provided on site, or existing
buildings on or near the site. Together with the required water, sewage, telecommunication, internet and electricity services these shall be
known as the Engineer’s site facilities. (The Engineer’s site facilities shall be provided by the Contractor for the duration of the Contract to house
the Engineer’s site personnel, accommodate all the materials testing equipment required to carry out the Engineer’s acceptance control testing
and to provide office space for the Engineer’s site personnel.)
A1.4.3 GENERAL
Where not already provided in the Contract Documentation, the Engineer shall furnish the Contractor with full details, in writing, regarding the
number, type, layouts and furnishing of all site accommodation, laboratories and offices required for the use of the Engineer’s site personnel.
The Contractor shall not order or make any arrangements for the provision of any buildings, materials, equipment or fittings on the basis of what
is specified or scheduled without written confirmation by the Engineer. No buildings shall be rented, purchased, erected, refurbished or altered
without the Engineer's written approval of the exact position, layout and orientation of the buildings.
Buildings for staff accommodation, laboratories and offices may comprise one or more of the following:
• Rented existing permanent structures in residential, business, industrial or farming areas.
• Temporary structures erected on property rented by the Contractor or on property provided by the Employer.
• Mobile structures parked on property rented by the Contractor or on property provided by the Employer.
• Permanent structures provided by the Employer.
Existing permanent structures may require refurbishment and partitioning to suit the requirements of the Engineer.
All buildings provided for the Engineer’s staff accommodation, laboratories and offices shall where possible be located in an area where landline
and/or cellular telecommunication and internet connectivity is available. If any of these services are not available dedicated services to that
effect shall be provided.
Unless otherwise specified in the Contract Documentation, or agreed to by the Employer, the buildings provided for the use of the Engineer’s
personnel shall be erected near the Contractor's construction camp. Should the Contractor decide to move the construction camp to a new site
during the construction of the Works, the buildings erected for the use of the Engineer shall be moved to the new site and re-erected if required
by the Engineer, or alternative buildings which meet the specified and the Engineer’s requirements shall be provided by the Contractor. No
additional costs related to moving the Engineer’s site facilities, or providing new site facilities, shall be incurred by the Employer or by the
Engineer and all such costs shall be borne by the Contractor.
The Contractor may not proceed with the permanent Works before the specified site accommodation, laboratory and office buildings required by
the Engineer have been provided, serviced and furnished by the Contractor. All the site accommodation, laboratory and office buildings shall be
provided as soon as possible after the Contractor has been given possession of the site of the Works and not later than six weeks after the
Contract commencement date.
If any additional site facilities are required by the Engineer during the construction of the Works, the Engineer shall inform the Contractor of the
additional requirements at least 30 calendar days before such additional facilities are required.
The Contractor shall be responsible for servicing the Engineer’s site facilities and for maintaining the facilities in a serviceable condition for the
duration of the contract.
The ownership of all offices, laboratories, housing, sanitary facilities, laboratory equipment, furniture, office equipment and other items provided
by the Contractor shall revert to the Contractor when the Engineer confirms in writing that he no longer requires them. The Contractor shall then
remove them from the site or terminate the rental lease for any rented buildings.
As specified in Clause A1.2.3.17 the Contractor shall provide adequate security measures to prevent unauthorised entry to the Engineer’s
offices, laboratories, site accommodation and any rented accommodation.
The Contractor shall ensure that all the site facilities and services provided comply with the applicable statutory and regulatory provisions,
building standards and health and safety requirements.

Where no specific designs for the Engineer’s site facilities are provided in the Contract Documentation or are provided by the Engineer, the
Contractor shall be responsible for the design of the Engineer’s site facilities. All the specified requirements shall be met and all applicable
legislative and regulatory requirements, building standards and health and safety requirements shall be complied with.
A1.4.5 MATERIALS
The Contractor shall be responsible for the selection and purchase of all materials required to provide the Engineer’s site facilities. The
Contractor shall ensure that the specified standards are met and that all applicable legislative and regulatory requirements, building standards
and health and safety requirements are complied with.

Not applicable to this Section.

A1.4.7.1 Offices and laboratories
a) General
The provision of new structures, and/or the refurbishment and alteration of existing permanent structures, shall be done with approved materials
in a manner which will provide adequate lighting, ventilation, insulation, noise damping and fire protection.
Temporary and mobile structures shall be constructed from approved materials. The buildings shall have double walls filled with insulating
material and lined on the inside with timber or other approved material. Ceilings shall be provided for all office and laboratory buildings. The
clear height of all offices between floor and ceiling shall be 2,4 m minimum.
Office buildings shall have timber floors or concrete floors covered with vinyl or ceramic floor tiles. Laboratory buildings shall have smooth, hard
concrete floors. Each building shall be provided with a roofed veranda on one side, running for the full length of the building. The verandas shall
be at least 1,5 m wide and shall have a 100 mm thick concrete floor.
Window areas of all buildings shall be at least equal to 25 % of the floor area and at least 40 % of the window area shall be able to be opened.
All windows for the offices and laboratories shall be provided with approved burglar proofing and with adjustable venetian blinds or similar
approved.
Each door shall be provided with a lock and two keys. All exterior doors shall be security doors of adequate strength fitted with a five-lever
security lock and/or a secure padlock.
Portable firefighting equipment shall be provided for all site offices and laboratory facilities in accordance with the requirements of the latest
statutory regulations and specifically with the requirements specified in SANS 10400-T:2011 Part T: Fire Protection. Fire extinguishers shall be
the all-purpose dry powder type manufactured in accordance with the requirements given in SANS 1910:2009 and shall be suitable for types A,
B and C fires. The extinguishers shall contain not less than 9,0 kg of extinguishing chemical and shall be installed, maintained and serviced by
competent persons in accordance with the requirements specified in SANS 1475-1 and SANS 10105-1.
Office and laboratory buildings shall be painted with an approved paint after erection. The paintwork shall be maintained during the Contract
Period.
All facilities shall include the provision of a single-phase electricity supply and, if specified in the Contract Documentation, a three-phase
electricity supply for the site laboratory.
Suitable description, designation or name boards with lettering 35 mm in height shall be affixed to each of the Engineer’s site offices and
laboratory buildings as directed by the Engineer.
All furniture, equipment and fittings provided by the Contractor shall be new unless otherwise agreed beforehand with the Engineer.
b) Offices
The various types of offices required shall be as instructed by the Engineer. Unless otherwise specified in the Contract Documentation, the
fittings, furniture and equipment shall conform to the following requirements:
• Office desks shall have a surface area of at least 1,5 m2 and shall be provided with at least three drawers, one of which can be locked.
• General-purpose steel cabinets shall have at least 1,5 m2 shelf area and a volume of 0,7 m3 each. Each cabinet shall have a lock with
two keys.
• Steel filing cabinets shall each be fitted with four drawers on runners. Each cabinet shall be fitted with a lock and shall be 1,3 m high,
460 mm wide and 600 mm from front to back.
• Shelves shall be suitable for storing all the contract files and documents.
• Electric power plug points shall be provided. Each office shall have at least two 15 ampere plug points.
• Lights shall be 1 500 mm, 58W fluorescent tubes or 1 500 mm, 22W LED tubes.
• Drawing tables shall have either an inclined or a horizontal drawing surface as may be required and a smooth top built to the
dimensions instructed by the Engineer.
• Draughtsman's stools shall be fitted with a padded seat with an adjustable seat height.
• The conference table shall be large enough to seat twelve persons and shall have a surface area of at least 4m 2.
• Chairs shall be robust and comfortable.
• A complete telecommunication and electronic data transfer service with uncapped Wi-Fi connectivity to the internet shall be provided for
the use of all the Engineer’s site staff. Where landlines are available the Engineer shall be provided with a direct independent telephone
line that is not connected to the Contractor's telephone exchange and which can accommodate the number of extensions requested by
the Engineer.
• The colour combination printer, copier, scanner machines shall be capable of printing on either A3 & A4 sized paper or only on A4 sized
paper as provided for in the Pricing Schedule.
• Blinds shall be either adjustable venetian blinds to permit light to enter the room or opaque roller blinds as specified and/or requested by
the Engineer.
• Notice boards and white boards shall be provided as specified or as required by the Engineer.
• Bookcases shall have at least three shelves, each with a minimum length of 0,9 m.
• Wall mounted pivot plan filing systems shall be complete with wall rack and pivot brackets to accommodate ten plan clamps where each
plan clamp can hold at least ten A0 size drawings.
• Where required by the Engineer, the Contractor shall provide and install air-conditioning units and heaters. Air-conditioning units shall
be of the wall mounted split unit inverter type capable of either cooling or heating a room. The capacity of the air-conditioning units shall
be adequate for the room area as recommended by the supplier thereof. Heaters shall be of a space-heating type without exposed
elements and shall have a capacity of not less than 1.5 kW each.
Where required by the Engineer, the following items shall be provided by the Contractor for his use:
• A rain gauge securely mounted on a pole in a position as indicated by the Engineer.
• A minimum and maximum atmospheric temperature gauge.
• An approved digital thermometer capable of measuring surface temperatures from -10oC up to +350oC.
• Mobile weather stations capable of measuring temperature, wind, chill, barometric pressure, UV levels, rainfall, wind direction and
speed. The device shall also have on-board storage capabilities for at least 7 (seven) days and shall include a USB PC connection with
software, allowing data to be downloaded electronically.
• A three metre aluminium straight edge complete with two wedges 200 mm long, tapering from 0 to 20 mm, calibrated in mm.
• A measuring wheel with a circumference of 1,0 m and equipped with a distance recording device.
• Approved first aid kits to be kept at the site office and/or laboratories and in the site staff vehicles.
c) Laboratories
All or any of four types of laboratories may be required - soils laboratories, bituminous materials laboratories, chemical laboratories and concrete
testing laboratories.
The actual sizes, layout and other details of the individual laboratory types shall be provided in the Contract Documentation or provided by the
Engineer.
Storerooms shall be provided, installed and furnished in the laboratory building. The sides of the storerooms shall be fenced off from floor level
to the ceiling with 50 mm diamond-mesh wire. Each store shall have a security door or gate of adequate strength fitted with a five-lever security
lock and/or a secure padlock.
The requirements for the laboratory fittings, furniture and equipment shall be as follows:
• The requirements for the laboratory furniture, the telecommunication and electronic data transfer service, printers, electricity plug points,
window blinds, air-conditioners, heaters and lights provided for the laboratories shall be the same as those specified for the Engineer’s
offices.
• Shelf space provided against walls shall be of robust construction capable of carrying the weight of material test samples and material
testing equipment.

• All work-benches shall be robust and their upper surfaces shall be 900 mm above floor level and shall include a robust timber shelf, 700
mm wide, capable of holding material samples, installed 400 mm above floor level. Work-bench surfaces shall be either of hard, smooth
wood that is free from warping or other defects or of concrete with a smooth, steel-trowelled finish.
• High stools for use at work-benches shall be robust and, if of fixed height, shall be 700 mm high.
• Where required, a 380 volt 3-phase electric power supply and three phase power points shall be positioned 1,2 m above floor level.
• Lights shall be 1 500 mm, 58W fluorescent tubes or 1 500 mm, 22W LED tubes.
• Gas installations shall include all the necessary gas cylinders, regulators, tubing and taps.
• Concrete working floors shall be at least 125 mm thick and provided with a hard, smooth finish. The working areas shall be either
entirely open or under a roof as may be required.
• Wash basins shall be as prescribed either of stainless steel or precast concrete with an area of at least 0,3 m2 and a minimum depth of
0,3 m. They shall be provided with swan-neck type laboratory taps and drain pipes.
• A supply of fresh clean potable water at a constant head of not less than 3 m at the taps shall be provided. Storage capacity in respect
of the laboratory water supply shall be not less than 5 000 litres. In addition to the taps at the laboratory sinks, a standpipe shall be
installed outside the laboratory on the concrete working floor, supplied with a tap fitted with a 30 m length of heavy duty, 20 mm internal
diameter, reinforced plastic hose pipe.
• Extractor fans, where required, shall be so mounted as to operate noiselessly. They shall have a capacity of at least 0.15kW each.
Extractor fans shall be spark proof.
• Fume cupboards shall be constructed in accordance with the details instructed by the Engineer.
• Where required, concrete footings and pedestals shall be constructed to the dimensions indicated by the Engineer for installing certain
testing equipment.
• When required, watertight baths for curing concrete test cubes, beams and cylinders shall be provided. The baths shall be rectangular
and located such that they are accessible from both longitudinal sides. The width shall not exceed 1,0 m and the depth shall not exceed
0,6 m. The baths shall be fitted with a circulating pump, a tap, a plug, a drain capable of completely emptying the tank and a
thermostatically controlled heating device to control the water temperature.
d) Car ports
Car ports shall be so constructed as to protect vehicles parked in them at all times against the direct rays of the sun. The car ports shall have
either a concrete floor or a layer of broken stone to alleviate dusty and muddy conditions. Each car port shall be at least 3,0 m wide, 6,0 m long
and 2,5 m high. The roofs of all car ports shall be water proof.
e) Areas around offices and laboratories
The access roads and parking areas at the offices and laboratories shall be treated to make them dust free, either with a layer of crushed stone
or with an approved bituminous surfacing. They shall be well drained and kept trafficable and free from mud at all times. Footpaths shall be
paved with concrete, interlocking blocks or paving slabs to provide convenient, all weather access to all buildings.
f) Ablution unit
An ablution unit with a clean potable hot and cold water supply and a water-borne sewerage system, including septic tanks if necessary, shall be
provided for the Engineer’s facilities. The ablution unit shall be established in a position that is easily accessible to both the Engineer’s offices
and the laboratory buildings. The ablution unit shall have separate rooms for males and females and each room shall have a floor area of at
least 6m2 with a lockable door and shall be equipped with:
• A 1 500 mm, 58W fluorescent tube or 1 500 mm, 22W LED tube.
• An opening window fitted with a blind,
• A vitreous enamel WC pan with a PVC seat and covers, a flush cistern and a toilet roll holder. The WC must be separate from the
entrance/basin area and it shall also have a lockable door.
• A vitreous enamel urinal with flush cistern in the male unit.
• A vitreous enamel wash basin.
• A mirror and a paper towel dispenser.
• A covered wastepaper bin next to the WC and another bin next to the towel dispenser.
Where specified in the Contract Documentation a separate shower and change room complete with shower, hot and cold running water and
drains shall also be provided.
g) Kitchen unit
The Contractor shall supply a kitchen unit with a clean potable hot and cold water supply for the Engineer’s offices with a minimum floor area of
6 m² and connected to the Engineer’s offices. The kitchen shall be equipped with:
• A 1 500 mm, 58W fluorescent tube or 1 500 mm, 22W LED tube.
• A single-bowl stainless steel basin with draining board, mounted on a cupboard unit.
• A hot and cold water supply, taps, a plug and a waste drain.
• A kitchen cupboard 1 m³ in volume with a melamine or similar counter top.
• A fridge with a capacity of at least 0,3 m3 with a separate freezer compartment with a capacity of at least a further 0,1 m 3.
• A microwave cooker, a kettle and a toaster.

• A cutlery set consisting of six knives, forks, dessert spoons and teaspoons, two kitchen knives, a cutting board, a can opener and a
bottle opener.
• A crockery set consisting of six dinner plates, six side plates, six bowls and six coffee mugs.
A1.4.7.2 Housing
a) Prefabricated houses
If prefabricated houses are scheduled to be provided by the Contractor the minimum requirements for the different types of houses that may be
required are as specified below, unless specified otherwise in the Contract Documentation.
The general requirements for all prefabricated house types shall be as follows:
• All rooms shall have concrete floors covered with vinyl or ceramic tiles in the bathroom and in the kitchen and with durable, wall to wall
carpets or carpet tiles in all the other rooms.
• The window area in each room shall be equivalent to at least 25 % of the floor area and at least 40 % of the total window area shall be
openable. All windows shall be provided with approved burglar proofing and adjustable venetian blinds or similar approved.
• All houses shall have a 220 volt single phase electricity supply and every room, except the bathroom, shall be provided with two 15
ampere electric plug sockets.
• Lights shall be 11 W compact fluorescent bulbs or 7W LED bulbs.
• The clear height of all rooms between floor and ceiling shall be at least 2,4 m. Every room shall have a ceiling with approved insulation
material installed above the ceiling.
• Each door shall be provided with a lock and two keys and all exterior doors shall be fitted with security doors of adequate strength with a
5-lever lock and/or a secure padlock.
• Portable firefighting equipment shall be provided for all site accommodation/housing in accordance with the requirements of the latest
statutory regulations and specifically with the requirements specified in SANS 10400-T:2011 Part T: Fire Protection. Fire extinguishers
shall be the all-purpose dry powder type manufactured in accordance with the requirements given in SANS 1910:2009 and shall be
suitable for types A, B and C fires. The extinguishers shall contain not less than 9,0 kg of extinguishing chemical and shall be installed,
maintained and serviced by competent persons in accordance with the requirements specified in SANS 1475-1 and SANS 10105-1.
• Each kitchen shall be equipped with:
− A single-bowl stainless steel basin with draining board, mounted on a cupboard unit with a clean potable hot and cold water supply,
taps, a plug and a waste drain,
− a kitchen cupboard 1,0 m³ in volume with a melamine or similar counter top,
− a fridge/freezer with a capacity of at least 0,5 m3 / 0,2 m3 for the fridge and freezer compartments respectively,
− a stove with an oven and four hot plates,
− a microwave cooker, a kettle and a toaster,
− a cutlery set consisting of six knives, forks, dessert spoons and teaspoons, two kitchen knives, two serving spoons, cheese grater,
cutting board, can opener and bottle opener,
− three cooking pots with lids and a frying pan and
− a crockery set consisting of six dinner plates, six side plates, six dessert bowls and six coffee mugs.
• Each bathroom shall be equipped with:
− A water borne sewage system with a septic tank if required,
− one vitreous enamel WC pan with a PVC seat and cover, a flush cistern and a toilet roll holder,
− one vitreous enamel bath with a clean potable hot and cold water supply, taps, a plug and a drain,
− one vitreous enamel wash basin with a clean potable hot and cold water supply, taps, a plug and a drain,
− a shower with a clean potable hot and cold water supply and a drain,
− a mirror and a towel rail and
− one covered wastepaper bin.
• Each bedroom shall be furnished with:
− Two three quarter sized beds - each bed supplied with a good quality sprung mattress, two fitted sheets, a duvet with two duvet
covers and two pillows with four pillowcases,
− a cupboard with a capacity of 1,5 m3, divided equally into a shelved section and a hanging section, and
− a chest of drawers with at least three drawers,
− Each lounge shall be furnished with a comfortable lounge suite consisting of a sofa and two lounge chairs and a coffee table.
− Each dining room shall be furnished with a dining room table and six dining chairs.
The houses shall be painted with an approved paint after erection. The paintwork shall be maintained in good condition for the duration of the
Contract.
The various house types that may be specified in the Contract Documentation shall have the number of rooms with their respective minimum
floor areas as shown in Table A1.4.7-1 overleaf. If other house types and/or size and/or furnishing requirements are required they will be

specified in the Contract Documentation. The Contractor shall submit details of the building type and quality and the proposed floor / room
layouts for the prefabricated houses to the Engineer for approval before any houses and furnishings are ordered and erected.
Table A1.4.7-1: House types
Rooms required and House type A House type B House type C
minimum floor areas (m2) Number of rooms Number of rooms Number of rooms
Main bedroom (20 m2) 1 1 1
Second bedroom (12 m2) 2 1 0
Lounge (20 m2) 1 1 1
Dining room (12 m2) 1 1 0
Kitchen (12 m2) 1 1 1
Bathroom (9 m2) 1 1 1
Covered veranda (12 m2) 1 1 1
Lockable storeroom (6 m2) 1 0 0
Covered car port (20 m2) 1 1 0
Total floor area (m2) 135 117 73
b) Rented accommodation
The Engineer shall usually be responsible for providing suitable accommodation for his site staff in a hotel, guesthouse, rented house or a
rented apartment in the nearest town or on a nearby farm.
The Engineer may instruct the Contractor to pay for any hotel or other accommodation or leased houses required. If so instructed by the
Engineer the Contractor shall enter into the necessary contracts for the lease of such accommodation as may be required and shall not
unreasonably object to the terms and conditions of such leases to be negotiated by the Engineer.
Where appropriate, and in the case where the rented accommodation is not deemed to be the primary residence of the site staff member, the
lease agreement shall include full compensation for a periodic garden service.
A1.4.7.3 Services
a) Sanitary arrangements
The Contractor shall be responsible for providing all sanitary services necessary for keeping latrines in a clean, neat and hygienic condition.
When no municipal sewage treatment is available, the Contractor shall provide the necessary septic tanks for all latrines. Waste water and
septic-tank effluent shall be taken into properly designed French drains. The Contractor shall also make provision for the removal of all rubbish.
Where the construction of septic tanks or a water-borne sewerage scheme is unfeasible, the Contractor shall provide conservancy tanks and
make arrangements for the removal and disposal of sewage.
b) Water, electricity and gas

The Contractor shall provide a constant supply of clean potable water suitable for human consumption as well as the necessary electric power
together with the required electrical network to the offices, laboratories and any site housing.
The power source shall be suitable for office and laboratory use with an anticipated large variance in load factor. Single phase power shall be
supplied at a nominal 220/250 volts and a nominal frequency of 50Hz to the offices and any site accommodation. If specified, three-phase
power shall be supplied at a nominal voltage of 400/231 volts and a nominal frequency of 50Hz to the site laboratory. The source of power shall
be either from a recognized power supply authority or by an onsite generator.
The electrical load shall be determined by an appropriate diversity factor being applied to the sum of the connected load, due allowance being
had for the starting load, efficiency and power factor of motors, or shall be estimated on the basis of 1.2kVA per m 2 of laboratory floor area
(three phase) and 0.35kVA per m 2 of office or site accommodation area. Allowance shall be made for a spare capacity of 15 % with a minimum
of 15kVA. A detailed load estimate shall be submitted to the Engineer for approval prior to any final arrangements being made for a source of
power.
The power supply shall be regulated by a suitable voltage regulator in order to maintain a constant current and voltage level at all times to
prevent damage to the office and laboratory equipment and related machinery during power surges. In the event of damage to the office and
laboratory equipment and related machinery because of a faulty voltage regulator, the Contractor shall be liable for payment of all repair or
replacement costs of such damaged items.
If specified in the Contract Documentation, a generator shall be provided on site to supply electricity if a constant, reliable source of electricity
from a power supply authority is not available on site. In the event of electricity being generated by the Contractor, the generator shall be
suitable to maintain the voltage so that it will not deviate by more than ± 5 % from the nominal voltage, and to maintain the frequency so that it
will not deviate from the nominal frequency by more than ± 2Hz over the entire load range from 0 % to 100 % of full load, also in the event of
switching on and off all normal loads connected to the supply. Power shall be available to the offices, any site accommodation and the
laboratory 24 hours per day every day of the year.
Should the Contractor require a stand-by generator to supply electricity for his own use when the power supply from the power supply authority
is interrupted it shall be supplied at his own cost.
Power shall be distributed by means of enclosed distribution boards with adequate weather and tamper protection, suitably rated circuit
breakers, earth-leakage units or fuses, and by means of adequately sized underground cables and earth conductors. Sizing of cables and rating
of protective and control devices shall take into account the load and fault currents that can occur on the system.
The reticulation network and the wiring installation of all buildings and structures shall be installed and maintained to ensure absolute safety and
a high standard of reliability, with particular reference to the earthing installation and the safety and protective devices. A certified, qualified
electrician shall provide a separate certificate of compliance for the electrical installation in each office, laboratory and site accommodation
building.

The Contractor shall at all times maintain the power supply, the distribution network and the wiring installation of all buildings and structures at
the highest standard of safety and usability.
The Contractor shall also supply liquid petroleum gas for the burners used in the laboratories and in the site office / site accommodation
kitchens if gas appliances have been provided.
A1.4.7.4 Maintenance of the Engineer’s site facilities and accommodation

The Contractor shall maintain the Engineer’s office, laboratory and site accommodation facilities in a clean, neat and tidy condition for the
duration of the Contract. The Contractor shall also maintain all the access roads to the Engineer’s site facilities including any publicly or privately
owned roads that the Engineer is making use of. Depending on the initial condition of the access roads this may entail repairing any potholes
and edge breaks of surfaced roads or the re-gravelling of the road and subsequently the regular watering, blading and rolling of the surface to
maintain a firm surface without excessive corrugations and loose materials. The Contractor shall ensure that the access roads to the Engineer’s
facilities are always in a safe and passable condition for normal cars under all weather conditions.
The Contractor shall provide all labour, equipment and material which may be necessary for keeping all the buildings in a neat and clean
condition. To this end the Contractor shall provide cleaners and sanitary personnel and shall supply all soap, toilet paper, linen roller towels,
cleaning aids and a refuse removal service.
The Engineer’s offices, laboratory buildings, kitchen, ablution units and any accommodation on site shall be cleaned daily.
Any repairs required shall be made immediately following a request from the Engineer.
A1.4.7.5 Office staff

If specified in the Contract Documentation the Contractor, in consultation with the Engineer, shall appoint an office secretary/receptionist and the
requested number of technical assistants to provide a continuous service to the Engineer’s site personnel.
These staff shall be paid by the Contractor including the provision of transport and other all other costs and benefits to the same extent as the
Contractor provides for his own employees of a similar grade.
The person selected as secretary/receptionist may have limited experience but must have the potential and be willing to receive training (both
formal and informal) to develop into a competent secretary / receptionist within a successful probation period of two months after appointment,
failing which the person shall be substituted.
The technical assistant/s shall be suitably educated with sufficient mathematical ability to perform the duties of a survey assistant, assistant
laboratory technician or an assistant quantity surveyor. Where available the technical assistant/s shall be student technicians who need to fulfil
their practical training requirements.
The Engineer shall be at liberty to accept or reject the staff offered.
A1.4.7.6 Site inspection transport

The Contractor shall provide a bus, mini-bus or combi van as and when required by the Engineer for site inspections and other technical
meetings for the use by him, the Employer, the Engineer and other invited persons.
The vehicle provided shall be in a mechanically sound condition, clean inside and outside, provided with a dedicated driver with the required
licence and PDP papers. It shall have all the necessary safety equipment and sufficient fuel to transport the passengers across the site and
surrounding areas as required by the Engineer.
A1.4.8 WORKMANSHIP
The applicable legislative and regulatory requirements regarding building standards and health and safety shall be complied with.

B1.4 FACILITIES FOR THE ENGINEER
CONTENTS
B1.4.1 SCOPE
B1.4.2 DEFINITIONS
B1.4.3 GENERAL
B1.4.5 MATERIALS

B1.4.8 WORKMANSHIP
B1.4.1 SCOPE
There are no additional labour enhancement requirements for Section A1.4.
B1.4.2 DEFINITIONS

C1.4 FACILITIES FOR THE ENGINEER
(i) Preamble
The tendered rate for each item shall include full compensation for providing, operating, maintaining and decommissioning upon completion, of all
the construction equipment, labour, tools, incidentals and supervision to carry out the activity or construct the works in the item, unless otherwise
stated.
Any prime cost or provisional sums shall be paid in accordance with the provisions of the conditions of contract. The charge or mark-up tendered or
allowed for is a percentage of the amount actually paid under the prime cost or provisional sum. This percentage shall cover all the Contractor’s
handling, supervision, profit and liability costs to provide the services in the prime cost or provisional sum item.
Dismantling, moving and re-erecting any or all of the Engineer’s facilities that may become necessary due to the Contractor’s decision to relocate his
own facilities will not be measured separately. The Engineer’s facilities will only be paid for once unless otherwise specified in the Contract
Documentation or if the Engineer specifically requests that they be moved for reasons other than relocation of the Contractor’s own facilities.
There are no payment related items mentioned in this Section that are measured in other Sections of the specifications.
The Contractor shall confirm the Engineer’s exact requirements before making arrangements for, ordering or supplying any of the items listed in the
pricing schedule for this Section.
With respect to payment items listed under payment item section numbers C1.4.1, C1.4.2 and C1.4.3 the following method of payment shall apply to
these items:
• 80 % of the amount due will be paid when the item is provided and erected, fitted or installed and taken over by the Engineer.
• A further 10 % will be paid when the value of all permanent work done, excluding escalation, exceeds one-half of the tendered amount.
• The remaining 10 % will be payable when the items have been removed from the site.

C1.4.1 Site accommodation
C1.4.1.1 Offices and conference room square metre (m2)
C1.4.1.2 Laboratories square metre (m2)
C1.4.1.3 Open concrete working floors and verandas square metre (m2)
C1.4.1.4 Roofs over open concrete working floors and verandas square metre (m2)
C1.4.1.5 Store rooms inside the laboratory square metre (m2)
C1.4.1.6 Car ports number (No)
C1.4.1.7 Ablution unit (equipped as specified) number (No)
C1.4.1.8 Change room with a shower number (No)
C1.4.1.9 Kitchen unit (equipped as specified) number (No)
C1.4.1.10 Type A prefabricated house (equipped as specified) number (No)
C1.4.1.11 Type B prefabricated house (equipped as specified) number (No)
C1.4.1.12 Type C prefabricated house (equipped as specified) number (No)
C1.4.1.13 Rented housing paid for by the Contractor provisional sum
C1.4.1.14 Contractor's handling costs, profit and all other charges in respect of item C1.4.1.13 percentage (%)
2
The unit of measurement for items C1.4.1.1 to C1.4.1.5 shall be the square metre (m ) of each facility, measured according to the internal floor area.
The contract rates shall include full compensation for the construction or provision of these Engineer’s facilities all complete in accordance with the
specifications given in the Contract Documentation. Where offices are provided in existing buildings the passageways, hallways and any other office
space in excess of the Engineer’s requirements shall not be measured for payment.
The unit of measurement for items C1.4.1.6 to C1.4.1.12 shall be the number of units provided. The contract rates shall include full compensation for
the construction or provision of these Engineer’s facilities all complete in accordance with the specifications given in the Contract Documentation.
The contract rates for items C1.4.1.1, C1.4.1.2, C1.4.1.3, C1.4.1.6, C1.4.1.7, C1.4.1.8,C1.4.1.9, C1.4.1.10, C1.4.1.11 and C1.4.1.12 shall also
include full compensation for clearing and grubbing the areas under and around the buildings, the excavation and backfilling of any foundations
required, the loading and hauling of the excavated material to spoil if required, regardless of haul distance, and the provision and maintenance of a
trafficable surface to provide all weather mud and dust free access for vehicles and pedestrians to and around the buildings.

The provisional sum allowed under item C1.4.1.13 shall provide for the cost of arranging and paying for rented accommodation for the Engineer’s site
staff and for providing services at the rented accommodation as instructed by the Engineer. The provisional sum shall be paid in accordance with the
provisions of the Contract Documentation.
The percentage under item C1.4.1.14 is a percentage of the amount spent under item C14.1.13 which shall include full compensation for all handling
costs, profit and all other charges in connection with arranging and paying for the rented accommodation.

C1.4.2 Items measured by area
C1.4.2.1 Shelving as specified, complete with brackets square metre (m2)
C1.4.2.2 Work benches with a concrete slab top square metre (m2)
C1.4.2.3 Work-benches with a wooden top square metre (m2)
C1.4.2.4 Constant-temperature baths of concrete and/or plastered brick square metre (m2)
C1.4.2.5 Concrete footings and pedestals for laboratory equipment square metre (m2)
C1.4.2.6 Roller blinds, opaque type square metre (m2)
C1.4.2.7 Venetian blinds square metre (m2)
C1.4.2.8 Notice boards square metre (m2)
C1.4.2.9 White boards square metre (m2)
C1.4.2.10 Galvanised wire mesh fencing for store rooms square metre (m2)
C1.4.2.11 Galvanised wire mesh store room gate with a padlock square metre (m2)
The unit of measurement for items C1.4.2.1 to C1.4.2.11 shall be the square metre (m2) of the item supplied and installed as specified. The area shall
be determined from the authorised outside dimensions in plan. The contract rates shall include full compensation for the construction or provision of
these items all complete in accordance with the specifications given in the Contract Documentation.

C1.4.3 Items measured by number
C1.4.3.1 Office swivel chair number (No)
C1.4.3.2 Office chair number (No)
C1.4.3.3 Draughtsman's stool number (No)
C1.4.3.4 Laboratory high chair number (No)
C1.4.3.5 Office desk with 3 drawers (at least one lockable drawer) number (No)
C1.4.3.6 Typist desk (L-shaped) number (No)
C1.4.3.7 Drawing table number (No)
C1.4.3.8 Conference table number (No)
C1.4.3.9 Bookcase number (No)
C1.4.3.10 Filing cabinet number (No)
C1.4.3.11 General purpose steel cabinet with shelves number (No)
C1.4.3.12 Wall mounted pivot plan filing system number (No)
C1.4.3.13 220/250 volt power outlet plug point number (No)
C1.4.3.14 400/231 volt 3-phase power outlet plug point number (No)
C1.4.3.15 Single 1 500 m, 58 watt fluorescent tube ceiling light number (No)
C1.4.3.16 Single 1 500 mm, 22 watt LED tube ceiling light number (No)
C1.4.3.17 11 watt compact fluorescent bulb ceiling light number (No)
C1.4.3.18 7 watt LED bulb ceiling light number (No)
C1.4.3.19 Wash-hand basin number (No)
C1.4.3.20 Laboratory basin number (No)
C1.4.3.21 Extractor fan number (No)

C1.4.3.22 Fume cupboard number (No)
C1.4.3.23 Fire extinguisher 9,0 kg, dry powder type number (No)
C1.4.3.24 Air-conditioning unit number (No)
C1.4.3.25 Heater number (No)
C1.4.3.26 Concrete specimen curing bath number (No)
C1.4.3.27 Waste paper basket number (No)
C1.4.3.28 UPS / Voltage stabiliser number (No)
C1.4.3.29 A3 / A4 colour printer, copier, scanner number (No)
C1.4.3.30 A4 colour printer, copier, scanner number (No)
C1.4.3.31 Rain gauge number (No)
C1.4.3.32 Minimum/maximum atmospheric temperature gauge number (No)
C1.4.3.33 Digital thermometer number (No)
C1.4.3.34 Mobile outdoor weather station number (No)
C1.4.3.35 3,0 m aluminium straight edge complete with two measuring wedges number (No)
C1.4.3.36 Measuring wheel number (No)
C1.4.3.37 First aid kit number (No)
C1.4.3.38 Standpipe complete with 30 m of 19 mm dia. heavy duty hose pipe number (No)
The unit of measurement for items C1.4.3.1 to C1.4.3.38 shall be the number of each item supplied and installed as specified. The contract rates
shall include full compensation for the provision and installation of these Engineer’s facilities all complete in accordance with the specifications given
in the Contract Documentation. On completion of the contract these items will be returned to the Contractor and the contract rates shall make
allowance for any depreciation in value over the duration of the contract period.

C1.4.4 Prime cost items
C1.4.4.1 Cell phones costs, including pro-rata rentals, for calls made in connection with contract prime cost sum
administration
C1.4.4.2 Handling costs and profit in respect of item C1.4.4.1 percentage (%)
C1.4.4.3 The provision of a direct independent telephone line for the Engineer, including the monthly prime cost sum
rental charges and the cost of business calls
C1.4.4.5 The provision of internet connectivity and WiFi data for Engineer’s site staff prime cost sum
C1.4.4.7 The provision of paper and ink for a combination colour printer/copier/scanner prime cost sum
C1.4.4.9 The provision of a complete 220/250 volt single phase electrical power installation, including all prime cost sum
poles, insulators, wiring, switchboards, mains connections, meters etc.
percentage (%)
C1.4.4.10 Handling costs and profit in respect of item C1.4.4.9
C1.4.4.11 The provision of a complete 440/231 volt three phase electrical power installation, including all prime cost sum
poles, insulators, wiring, switchboards, mains connections, meters etc.
C1.4.4.13 Provision of a 440/231 volt three phase electricity generator if electricity from a power supply prime cost sum
authority is not available on site
C1.4.4.15 The provision of all gas installations required at the site offices, laboratories and at the prime cost sum
Engineer’s staff accommodation (if required), including gas storage cylinders, tubing,
regulators, gas burners and shut-off cocks

The unit of measurement for items C1.4.4.1, C1.4.4.3, C1.4.4.5, C1.4.4.7, C1.4.4.9, C1.4.4.11, C14.4.13 and C1.4.4.15 is the prime cost sum which
shall be the invoiced cost of these items.
The percentage for items C1.4.4.2, C1.4.4.4, C1.4.4.6, CC1.4.4.8, C1.4.4.10, C1.4.4.12, C1.4.4.14 and C1.4.4.16 is a percentage of the amount
spent under the relevant prime cost item. It shall include full compensation for the handling costs of the Contractor and the profit for providing the
specified service.

C1.4.5 Services at site offices, laboratories and site accommodation
C1.4.5.1 Fixed costs lump sum
C1.4.5.2 Running costs month
The unit of measurement for item C1.4.5 shall be the lump sum. The lump sum shall include full compensation for all costs, administration charges
and other general costs related to providing the specified services for the Engineer’s site facilities. These services include the provision of a potable
water supply, a sewerage system, septic tanks, conservancy tanks, refuse containers etc. as well as the excavation and backfilling of any service
trenches required and the loading and hauling of the excavated material to spoil if required, regardless of haul distance.
The unit of measurement for item C1.4.5.2 shall be the month or part thereof for the duration of the approved contract period. The contract rate shall
include full compensation for the provision of electricity and gas, sewage removal, refuse and rubbish removal, cleaning services, maintenance and
repairs as specified and required. The contract rate shall also include the partial cost, proportional to the amount of electricity supplied to the
Engineer’s offices, laboratory and site accommodation, of running a generator only when electricity from a power supply authority is not available on
site.

C1.4.6 Office staff
C1.4.6.1 Secretary / receptionist month
C1.4.6.2 Technical assistant month
The unit of measurement for items C1.4.6.1 and C1.4.6.2 is the month or part thereof for the duration of the approved contract period. The contract
rate shall include full compensation for providing the specified staff member and for all wages, Employer contributions, accommodation, transport and
other staff related costs incurred by the Contractor.

C1.4.7 Site inspection transport
C1.4.7.1 Provision of a bus, mini-bus or combi van for site inspection purposes (specify type and size of per day
vehicle)
C1.4.7.2 Travel on site kilometre (km)
The unit of measurement for item C1.4.7.1 is a day regardless of the number of hours that the vehicle is used during that day. The contract rate shall
cover all the costs of providing the specified vehicle with an experienced licensed driver when required by the Engineer.
The unit of measurement for item C1.4.7.2 is the total kilometres travelled during the site inspection by the vehicle, as instructed by the Engineer. The
contract rate shall include full compensation for all fuel, maintenance and depreciation costs. Any kilometres covered in delivering and removing the
vehicle from site will not be measured for payment.

C1.4.8 Site security measures for the Engineer’s facilities
C1.4.8.1 Supply and installation of all required security measures at the Engineer’s site offices and lump sum
laboratories
C1.4.8.2 Provision of security guards / watchmen and an armed response service at the Engineer’s site month
offices and laboratories
C1.4.8.3 Supply and installation of all required security measures at the Engineer’s site accommodation lump sum
C1.4.8.4 Provision of security guards / watchmen and an armed response service at the Engineer’s site month
accommodation
C1.4.8.5 Supply and installation of an alarm system at the Engineer’s rented accommodation (No. of lump sum
houses stated ………)
C1.4.8.6 Provision of an armed response service at the Engineer’s rented accommodation (No. of month
houses stated ………)
The unit of measurement for items C1.4.8.1 and C1.4.8.3 is the lump sum. The lump sum shall include full compensation for the provision of all
security measures required at the at the Engineer’s site office, site laboratory and site accommodation as specified in Clause A1.2.3.17.
The unit of measurement for items C1.4.8.2 and C1.4.8.4 is the month or part thereof that the services are provided at the engineer’s site office, site
laboratory and site accommodation as specified in Clause A1.2.3.17. Part of a month shall be calculated to two decimal places.

The unit of measurement for item C1.4.8.5 is the lump sum per house. The lump sum shall include full compensation for the provision of an alarm
system at the Engineer’s rented accommodation as specified in Clause A1.2.3.17.
The unit of measurement for item C1.4.8.6 is the month or part thereof per house that an armed response service is provided at the engineer’s rented
accommodation as specified in Clause A1.2.3.17. Part of a month shall be calculated to two decimal places.

D1.4 FACILITIES FOR THE ENGINEER
CONTENTS
D1.4.1 SCOPE
D1.4.2 GENERAL
D1.4.1 SCOPE
Certificates showing compliance with the applicable SANS Specifications referred to in Clause A1.4.7 in this Section shall be provided by the
Contractor if requested by the Employer or the Engineer.
Regulatory compliance certificates for the electrical wiring and gas supply installations at the site accommodation, laboratories and offices shall
be submitted to the Engineer upon completion of the various facilities and before any payment is made for these facilities.

1.5 ACCOMMODATION OF TRAFFIC
CONTENTS
A1.5.1 SCOPE
A1.5.2 DEFINITIONS
A1.5.3 GENERAL
A1.5.4 DESIGN BY THE CONTRACTOR / PERFORMANCE BASED SYSTEMS
A1.5.5 MATERIALS
A1.5.8 WORKMANSHIP

A1.5 ACCOMMODATION OF TRAFFIC

A1.5.1 SCOPE
This Section covers the accommodation of vehicular and non-motorised traffic and pedestrians on, over or through the site of the Works. This
involves:
• The construction, maintenance and eventual removal of temporary deviations and detours.
• The construction and eventual removal, if required, of temporary gates, fences, drainage works and other incidental items that may be
required.
• The provision, erection, relocation, maintenance and removal of traffic control facilities and traffic safety items.
• Painting and removal, if required, of temporary road markings and placing of temporary road studs.
• The issuing of public notices.
• Liaison with the relevant traffic authorities, motorists and other affected persons.
• The removal and reinstatement/landscaping of temporary deviations when they become redundant.
The purpose of providing the traffic accommodation measures discussed in this Section is to ensure the safety of road users, pedestrians and
the Contractor’s and Engineer’s employees who are engaged on the Works.
A1.5.2 DEFINITIONS
Barriers - consist of concrete, plastic or steel sections which are placed across or along the road to stop or divert the traffic or alongside /
around the work area to separate the traffic and pedestrians from the work area. Barriers may be used either as channelization devices or as
vehicle restraining systems depending on their type and on their fixing arrangements.
Channelization devices - moveable channelization devices used for diverting and/or separating vehicles, non-motorised traffic and pedestrians
from the work areas include barriers, delineators and traffic cones. These moveable channelization devices may be supplemented by additional
temporary road markings and road studs.
Delineators - are rectangular warning signs with a directional chevron on one or both sides which indicates which side of the roadway is open
for use by the vehicles, non-motorised traffic and/or pedestrians.
Detour - a detour is any section of another existing road onto which traffic is diverted around the work areas.
Road markings - include all the regulatory road markings painted on the surface of existing or newly constructed roads as well as temporary
road markings painted on the surface of deviations and detours.
Partial width or half width construction - this is a construction strategy wherein part of a roadway is constructed or reconstructed/rehabilitated
as a phase without encroaching on the remaining width of the roadway in order to accommodate traffic. (Typically, a two-lane two-way road will
usually be constructed in two half width phases whereas a multi-lane road will be constructed in several partial width phases.)
Road signs - include all the regulatory road signs erected along existing or newly constructed roads as well as the temporary road signs
erected along temporary deviations and detours.
Road restraint systems - temporary road restraint systems used for preventing vehicles from leaving the permitted lanes, or for separating two
opposing streams of traffic, during the construction of the Works may consist of either movable precast concrete or steel barriers or steel
guardrails that comply with the specifications given in Chapter 11.

Temporary deviation - a temporary deviation can be partial width, single or multi-lane roads that are used to accommodate vehicular and non-
motorised traffic while the Works are in progress. They are either a portion (part width) of the road that is under construction or they are newly
constructed roads (with a gravel or a bituminous surface) constructed alongside or in close proximity to the Works.
Traffic - means all vehicles, non-motorised vehicles and pedestrians that need to pass around, alongside or through the work areas.
Traffic control facilities - include flagmen, portable STOP and GO signs, portable barriers, temporary road signs and traffic signals.
Traffic calming devices - are used to reduce vehicle speeds and they generally consist of temporary or permanent rumble strips, humps or
circular bumps placed in an overlapping strip pattern across the width of the traffic lane/s.
Traffic safety devices - include flashing warning lights, illuminated and/or flashing traffic arrows and signs, electronic variable message boards,
vehicle restraint systems, impact attenuation devices and guardrails.
A1.5.3 GENERAL
A1.5.3.1 Access to properties
The Contractor shall provide and maintain access to all public and private properties which fall within or adjoin the Works at all times, unless
alternate provision is specified in the Contract Documentation.
A1.5.3.2 General requirements

The Contractor may not commence any part of the Works until adequate provision has been made for the accommodation of vehicular, non-
motorised and pedestrian traffic. Traffic shall be accommodated in accordance with the requirements given in the Contract Documentation
unless the Contractor has submitted an alternative incorporating an amended method of traffic accommodation and this alternate method has
been accepted by the Employer.
The Contractor shall ensure that all employees and all visitors to the site are equipped with approved safety vests / jackets utilizing retro-
reflective and/or fluorescent panels in red, yellow, white and/or silver and that the safety vests/ jackets are worn whenever his personnel and
visitors are on the site of the Works. Any person found not wearing a safety vest/jacket while on the site of the Works, including any of the
Engineer’s or the Employer’s staff, shall be instructed to leave the site until they are in possession of and wearing a safety vest/jacket. All safety
vests/jackets shall be kept clean and in good condition and any safety vests/jackets that are, in the opinion of the Contractor’s safety officer
and/or the Engineer, ineffective shall be immediately replaced by the Contractor, Engineer or Employer, as applicable.
The Contractor shall be responsible for maintaining all existing or temporary road surfaces within, and on the approaches to, the Works area in
a safe and trafficable condition at all times of the day or night for the duration of the contract. Any construction material that is driven onto or spilt
on temporary roads, public roads or privately-owned roads during the haul of material, or while any construction operations are being carried
out, shall be cleaned off the road surface as soon as practically possible and removed to an approved spoil site.
During non-working hours, or when construction work is not taking place on a certain section of road, all superfluous obstructions to the traffic
shall be removed and all signs no longer applicable to the situation shall be removed to an approved safe location or effectively covered with an
opaque, weather proof material bag made from durable material that is firmly fixed over the sign.
The overnight parking of construction vehicles and/or equipment within the road reserve may be permitted in areas alongside the road
carriageway, in consultation with the Engineer. The minimum clearance between the parked vehicles and/or equipment and the edge of the
nearest traffic lane shall be 6,0 m. The parked equipment and vehicles shall be placed behind reflective chevron delineators which are placed to
face the traffic at a maximum spacing of 10m between each delineator.
If the construction vehicles and/or equipment need to be parked overnight closer than 6,0 m from the nearest traffic lane, then they shall be
separated from the lane by guardrails correctly installed on guardrail posts or by vehicle restraining systems which consist of concrete or steel
barriers correctly placed, assembled and fastened together in a sufficient length to create an effective vehicle restraint system. The guardrails or
vehicle restraining systems shall be fitted with red reflectors or reflective chevron signs which are fixed to face the traffic at a maximum spacing
of 10 m between each reflector or reflective chevron sign. The use of drums, lightweight plastic barriers, concrete or steel barriers that are not
correctly placed and fastened together or guardrails that are not attached to correctly installed guardrail posts will not be permitted.
When requested by the Engineer, the Contractor shall provide lane closures for road inspections and testing. This must be done in advance of
the actual time programmed for the inspection and testing work.
A1.5.3.3 Lane width

The clear width of any traffic lane which is provided along any section of a detour, a temporary deviation or any partial / half width construction
area shall not be less than 3,5 m unless a narrower width is specified in the Contract Documentation or approved by the Engineer in writing. If a
lane width less than 3,5 m is specified or approved by the Engineer then temporary width restriction warning signs shall be erected at approved
locations along the narrow section of the detour, temporary deviation or partial / half width construction areas.
A1.5.3.4 Late occupation of traffic lanes, interchange ramps and cross roads
If specified in the Contract Documentation the Contractor shall be charged a lane occupation levy for any occupation of traffic lanes, interchange
ramps and any cross roads beyond the completion dates and times agreed with the Employer. The lane occupation levies shall be specified in
the Contract Documentation and they shall be deducted from payments due on the relevant interim payment certificates. If specified in the
Contract Documentation the Contractor shall also be charged a lane occupation levy for traffic lanes, interchange ramps and cross roads
occupied by the Contractor for the purpose of carrying out remedial work during or after completion of the Works.
A1.5.3.5 Legal requirements

In addition to the specifications given in the Contract Documentation all traffic accommodation arrangements shall also conform to the
specifications and provisions given in the latest edition of the South African Road Traffic Signs Manual (SARTSM) and all other current
legislation and regulations.
The Contractor shall make use of approved methods to control the movement of his equipment and vehicles so as not to constitute a hazard on
the road. His staff and operators shall obey the permanent and temporary road traffic signs at all times and shall not consider themselves
exempt from the road traffic laws and regulations because the Contractor has been given occupation of the site of the Works.

The Contractor shall indemnify the Employer against all proceedings, claims, actions, damages to vehicles or property, injury or death of
persons and all costs which may arise from, or be related to:
• The absence, improper functioning or incorrect placement of road traffic signs, barriers, channelization devices, road markings, traffic
control facilities, traffic safety devices and vehicle restraint systems.
• Any construction related items, materials or surfacing aggregates that were dropped, deposited, spilt, left or come loose from any
access roads, haul roads, detours, temporary deviations and newly opened sections of completed roads.
The Contractor shall submit written confirmation that his insurance cover complies with the requirements specified in the Contract
Documentation and shall supply a copy of the relevant insurance policy/policies to the Engineer for his records.
The Contractor shall within seven calendar days after receipt of a third-party claim acknowledge receipt to the claimant and submit the claim to
his insurance company for processing. The Contractor shall then follow up the processing of the claim and inform the claimant of the outcome
as soon as the matter has been dealt with by the Contractor’s insurance company. The Engineer shall be copied on all correspondence
regarding third party claims. The Contractor shall report on the latest status and outcome of all the third-party claims at every site meeting.
A1.5.3.6 Other traffic control measures ordered by the Engineer

The Engineer may instruct the Contractor to provide any other road sign, reflective tape, etc. not measured in standard payment items. Such
road signs shall conform to the requirements given in Volume 2 of the SARTSM and/or specified in the Contract Documentation or by the
Engineer in writing. To ensure that the travelling public is kept fully informed and warned on matters relating to the accommodation of traffic,
construction sign posting and the effect of the construction on the free flow of traffic through the site, the Engineer may instruct the Contractor to
arrange for advertising in the press, on the local radio stations and/or for other forms of publicity.
A1.5.3.7 Penalty events

Whenever the Contractor fails or refuses to take the necessary steps to ensure the safety and convenience of the public and/or to accommodate
the traffic, pedestrians and non-motorised traffic and maintain the temporary detours, deviations, traffic accommodation facilities and traffic
safety devices correctly in accordance with all the requirements and specifications given in the Contract Documentation, the Contractor shall be
subject to the following penalty conditions:
• A fixed penalty amount as stated in the Contract Documentation per occurrence shall be deducted for each and every occurrence of
non-compliance.
• A time-related penalty amount as stated in the Contract Documentation per hour over and above the fixed penalty shall also be
deducted for non-compliance to rectify any defects in the accommodation of traffic requirements within the allowable time after the
Engineer has given an instruction to this effect. The Engineer's instruction shall state the allowable time, which shall be the time in hours
for reinstatement of the defects. Should the Contractor fail to adhere to this instruction, the time-related penalty shall be applied from the
time the instruction was issued.
A1.5.3.8 Property pegs and survey beacons

Temporary deviations shall be constructed so as not to damage or displace existing cadastral beacons or trigonometrical-survey beacons. In
exceptional cases where this is not possible, the Contractor shall notify the Engineer in good time so that the Engineer can arrange to have
them suitably referenced before they are displaced. Cadastral beacons shall be replaced at the cost of the Contractor, unless removal is
specified by the Engineer.
A1.5.3.9 Right of way

The travelling public shall have the right of way on public roads, existing roads used as detours and on all temporary deviations for the entire
contract period. The Contractor shall make use of approved methods to control the movement of the construction equipment and vehicles so as
not to constitute a hazard on the road or impede the public right of way.
A1.5.3.10 Safety of the travelling public and the Contractor’s employees

The safety of the travelling public, and of the Contractor’s and the Engineer’s employees is of paramount importance and shall take priority over
all aspects of the Works. The Contractor shall be responsible for the safe and easy passage of all vehicular, non-motorised and pedestrian
traffic past and/or over the Works in a manner which will protect the road users, pedestrians, the Contractor’s employees and the Engineer’s
employees.
A1.5.3.11 Services
Services affected by temporary deviations shall be located, protected and relocated in a similar manner as services affected by the permanent
Works as specified in Clause A2.1.3.2 of Chapter 2. The requirements given in the Contract Documentation shall also be applicable to any
services affected by the construction of temporary deviations.
A1.5.3.12 The use of public roads by the Contractor

The Contractor shall have the right to use public roads, including any detours and temporary deviations open to public traffic, subject to the
provisions and restrictions specified in Clause A4.1.7.1 of Chapter 4 and in the Contract Documentation.
A1.5.3.13 Traffic over completed pavement layers and structures

Traffic over the completed pavement layers and structures on an uncompleted road shall be restricted to the vehicles and equipment required
for the construction of the remaining Works. All construction vehicles will be restricted to the maximum axle loads permitted on public roads by
the statutory provisions.
If it is necessary to temporarily accommodate public traffic over the completed pavement layers and structures on an uncompleted road this
shall only be done if agreed to by the Engineer.
The Contractor shall be responsible for protecting and maintaining the pavement layers. Any damage to the layers shall be repaired or rectified
at the Contractor’s own cost unless the Engineer agrees in writing to pay for some or all of these costs.

A1.5.3.14 Vertical clearance
The minimum vertical clearance over any section of a temporary deviation shall be 5,2 m. If the minimum vertical clearance is less than 5,2 m
then approved warning signage shall be erected at approved locations on the overhead obstruction itself as well as in advance of the
obstruction. The advance warning signs shall be erected at distances of 1,0 km, 400 m and 200 m in advance of the overhead obstruction.
The warning signs shall show the actual clearance height in metres (to 2 decimal places) less a safety allowance of at least 75 mm.
Where the overhead obstruction or its support structure is likely to collapse if it is struck by a vehicle or by its load, and thereby represent a
danger to the public or to the persons working on the site, then such an obstruction shall, in addition to the warning signs, have an approved
height restriction warning gantry erected at least 200 m in advance of the overhead construction, or at the distance specified in the Contract
Documentation or specified on site by the Engineer. The lower edge of the warning gantry shall be at least 5,2 m above the road surface and
reflective chevron plates, spaced not more than 0,3 m apart, shall be suspended beneath the gantry to the same height above the road surface
as the overhead obstruction less a safety allowance of 75 mm. The warning gantry shall be fitted with a beam triggered alarm that is audible to
all employees working on the obstruction over the road. A properly trained flagman shall also be placed on the side of the road 50 m after the
warning gantry to wave down and stop any vehicles whose loads touch any of the chevron warning plates.
Where the temporary deviation passes under a high voltage electric powerline the minimum vertical clearance height specified by the service
owner shall be provided.

If, during the Contract, the Contractor would like to amend any of the specified traffic accommodation arrangements he shall provide his reasons
for doing so in writing and obtain the Engineer's prior written approval. If the Engineer's prior written approval has been obtained, the Contractor
will be remunerated for the revised traffic accommodation arrangements in accordance with the contract rates only up to an amount that does
not exceed the tendered amount for the specified traffic accommodation arrangements that have been replaced.
A1.5.5 MATERIALS
A1.5.5.1 Material used for construction of temporary deviations
All material required for the construction of temporary deviations, which includes the earthworks, pavement layers, stabilised layers, asphalt and
bituminous surfacing layers shall comply with the specifications for these materials given in Chapters 4, 9 and 10 respectively.
A1.5.5.2 Temporary culverts

Temporary culverts of the type and size required shall comply with the specifications given in Section A3.2 of Chapter 3 as well as with any
additional specifications that may be given in the Contract Documentation.
A1.5.5.3 Temporary road restraint systems

Where specified in the Contract Documentation or instructed by the Engineer, the Contractor shall provide, install, move and re-install and
subsequently remove temporary road restraint systems, if so required for the construction of temporary deviations.
All work shall be carried out in accordance with the specifications given in Section A11.4 of Chapter 11.
A1.5.5.4 Temporary fencing and gates

Where specified in the Contract Documentation or instructed by the Engineer, the Contractor shall provide either new fencing and gates, or
move and subsequently reinstate existing fencing and gates, if so required for the construction of temporary deviations.
All work shall be carried out in accordance with the specifications given in Section A11.5 of Chapter 11.
A1.5.5.5 Temporary road signs

Temporary road signs shall comply with the specifications given for road signs given in Section A11.6 of Chapter 11.
A1.5.5.6 Temporary road markings and road studs

Temporary road markings and road studs shall comply with the specifications given for permanent road markings and road studs given in
Section A11.7 of Chapter 11.
A1.5.5.7 Traffic accommodation facilities and safety devices

All road signs, barriers, channelization devices, guardrails, reflectors and other traffic safety devices shall be manufactured with materials that
comply with the specifications given in the latest current edition of Volume 2 of the SARTSM, or any applicable international design standards
that may be given in the Contract Documentation, and in accordance with the specifications given in Sections A11.4.5 and A11.6. of Chapter 11
as well as any additional specifications that are given in the Contract Documentation.

Specifications for the traffic control facilities and traffic safety items are given in the following Clauses A1.5.6.1 to A1.5.6.4.
A1.5.6.1 Traffic control facilities

a) Barriers
Barriers manufactured from plastic and ballasted with sand or water, shall only be used to barricade work areas to close off sections of the
Works from members of the public and non-motorised traffic. They shall not be used to prevent vehicular traffic from encroaching on or entering
the work zone except at stop/go points where they may be used to supplement the stop/go sign or traffic signal which is operated by the traffic
controller.

Where specified in the Contract Documentation, steel guardrails may be used as channelization devices provided they comply with the specified
requirements and are installed as specified in Clauses A11.4.4, A11.4.5 and A11.4.7.2 of Chapter 11. They may not be affixed to drums or other
moveable objects. Guardrails shall not be used for the purpose of preventing heavy vehicles from leaving the permitted lanes or deviations and
the Contractor shall use approved vehicle restraining systems for this purpose.
Temporary road restraint systems which are erected for the purpose of preventing vehicles from leaving the permitted lanes or deviations shall
be movable barriers manufactured from steel or concrete with an approved safety shape design (e.g. New Jersey, F-shape or single slope). The
movable barriers shall be obtained from approved suppliers and placed between the trafficked lane/s and/or the construction areas. They shall
comply with the specified requirements and be installed as specified in Section A11.4 of Chapter 11 which refers to either of the following
specifications:
i. The European Specification EN 1317 with a minimum containment level H1 or as indicated in the Contract Documentation
or
ii. The American Federal Highways Administration Specification AASHTO MASH, or NCHRP 350 where no MASH compliant device
is available, with a minimum containment level TL4 or as indicated in the Contract Documentation.
The terminal sections of the moveable barriers may be a proprietary type, or may be Contractor designed, to attenuate head-on impacts of at
least Test Level TL2 (70 km/hr) in accordance with AASHTO MASH, or NCHRP 350 where no MASH compliant device is available, or at least
EN1317 Containment Level P2 for End Terminals or 80/1 for Crash Cushions or as specified in the Contract Documentation.
Where specified in the Contract Documentation, the temporary road restraint restraining system selected shall have removable sections to
permit crossing points for emergency vehicles. These sections shall be fully integrated with the restraining system and provide a continuous
restraint without compromising on the specified containment level or working width when closed. These sections shall be easy to open with
minimal personnel in under 10 minutes without the need for special tools and plant. The removable sections shall be located at a maximum
spacing of 2 kilometres or as specified in the Contract Documentation.
b) Delineators
Delineators shall comply with the manufacturing and reflective requirements of SANS 1555. In addition, they shall also:
• Have blades that are reversible with dimensions as specified in the SARTSM and/or as indicated in the Contract Documentation.
• Be manufactured from durable, impact resistant plastic material.
• Be designed such that they, together with their mounting base, will collapse in a safe manner under traffic impact.
• Have the lower edge of the reflective part of the delineator mounted at least 100 mm above the road surface.
• Be capable of withstanding the movement of passing heavy vehicles travelling at speeds of up to 80 km/hr and gusting winds with a
wind speed of up to 60 km/h without falling over. The base area shall be at least 0,18 m2 and ballasted by its own weight or with durable
sandbags filled with fine, clean sand of adequate mass. (The sand bags shall be partially filled to ensure a flattish surface without
bulging and they shall not be filled with anything other than fine, clean sand).
c) Temporary signs
All temporary signs shall be manufactured to the sizes and in accordance with the specifications given in Volume 2 of the SARSTM and in
Section A11.6 of Chapter 11 as well as with any additional specifications that are given in the Contract Documentation.
d) Traffic cones
Traffic cones shall be manufactured in a fluorescent red-orange or red impact resistant plastic material. The minimum height of traffic cones
shall be 750 mm. The design and weight of the traffic cone shall be such that it will not be displaced or blown over by passing heavy vehicles
travelling at speeds of up to 80 km/hr and gusting winds with a wind speed of up to 60 km/h.
e) Traffic signals
Temporary traffic signals shall conform with the requirements of traffic signals and conform to the size and visibility requirements specified for
permanent traffic signals in Volume 3 of the SARTSM. The traffic signals shall be provided with either a permanent electricity supply or with a
generator and/or batteries that are capable of powering the signals continuously for the full duration that they are required to be operational.
Temporary traffic signals used for manual control of vehicles in alternate directions shall be actuated to turn green for adjustable green phases
and thereafter automatically default to red to ensure that two directional green is avoided should operators be absent or in-attentive.
f) Traffic control stations
Traffic control stations shall be provided at each traffic control point that is in operation during hours of darkness. They shall have the following:
• A trained traffic controller.
• An effective communication system that allows the controllers at each end of the deviation to communicate effectively with each other.
• An all-weather shelter with at least three square metres floor area fitted with a clear window facing the oncoming traffic that can be
opened if required and a stable door.
• A portable chemical toilet that shall be regularly maintained.
• A red/green stop/go electric traffic signal system consisting of two No. 200 mm diameter LED cluster lights mounted in circular light
shields on a backing board attached to 3,0 m high steel poles complete with all electrical wiring.
• A 400W metal halide or a 100W LED floodlight mounted on a 9,0 m high steel pole to illuminate the traffic control point as well as the
approach to the traffic control station where the traffic will start to queue. The light must shine downwards and shall be positioned so
that it does not shine towards oncoming vehicles.
• Additional 400W metal halide or 100W LED floodlights mounted on 9,0 m high steel poles to adequately illuminate the full length of the
vehicle queuing area (number and spacing to be discussed with the Engineer and amended to suit varying traffic conditions whenever
necessary). The lights must shine downwards and shall be positioned so that they do not shine towards oncoming vehicles.
• An electrical power supply to operate the traffic signal lights and the floodlights at each traffic control point that is capable of
continuously powering the lights for the full duration that they are required to operate.

• A moveable yellow or orange barrier fitted with a STOP sign facing the oncoming traffic to prevent vehicles from utilising the closed road
lanes. The barrier shall be moved by the traffic controller to open and close the relevant lanes for road users as required.
A1.5.6.2 Illuminated traffic signs and safety devices

a) Flashing illuminated arrow board
The illuminated arrow board shall be made up of LED light sources powered by battery or other suitable means, mounted on a backing board. A
single shaft arrow will be required that can be used for both left and right directions. This illuminated flashing arrow board shall be used at lane
drops on multi-lane highways or at other locations as directed by the Engineer.
b) Illuminated road signs
The illuminated road signs shall be made up of LED light sources powered by battery or other suitable means, mounted on a backing board.
The illuminated colours must match the regulation sign colours specified in the SARTSM. If specified in the Contract Documentation, these
illuminated road signs shall be used on multi-lane and/or heavily trafficked highways during night time hours.
c) Mobile Variable Message Sign
The Variable Message Sign (VMS) shall be mounted on a trailer and located in a safe position where it is easily seen by the travelling public. It
is used to provide information regarding the road and/or traffic conditions ahead or to inform a motorist of his actual travelling speed.
The mobile VMS system must be equipped with solar panels combined with deep cycle batteries to provide an output of at least 600W. It shall
be capable of withstanding shocks up to 3G and wind speeds up to 120 km/h.
The sign face shall not be less than 3,0 m2 to provide a full matrix LED with at least 2050 pixels per square metre. Each pixel shall have a LED
and the pixel spacing shall not be less than 25 mm. The sign shall be able to display any configuration which contains letters, symbols, icons
etc. The cone of vision is to be 30º and the light intensity must be automatically controlled by a daylight sensor; the light intensity shall also be
capable of being controlled manually.
The lower edge of the sign face shall be at least 1,5 m above ground level.
The information displayed on the VMS sign face shall be controllable remotely from a computer via an internet connection.
d) Sign mounted flashing lights
Sign mounted flashing lights shall consist of two rectangular amber flashing lights, each at least 120 mm wide x 45 mm high using 10W LED’s.
The lights shall be visible from a distance of at least 800 m.
Depending on the width of the advance warning signs, the two flashing lights shall be mounted either 900 mm apart centre to centre on a 1 200
mm wide x 200 mm high white non-reflective sign board or mounted 600 mm apart centre to centre on a 900 mm wide x 150 mm high white
non-reflective sign board.
The sign board with the two flashing lights shall be mounted on top of each of the first advance warning signs positioned before the start of
temporary deviations, lane closures, stop/go points for one-way traffic zones, vertical height restrictions and at any other potentially hazardous
positions. They shall be placed where specified in the Contract Documentation or by the Engineer.
The lights shall have a separate solar panel power source with batteries that are mounted in a lockable steel box mounted on the back of the
sign board. The power supply shall be sufficient to power the lights for at least 12 hours and the batteries shall be replaced or recharged as
necessary to ensure that the flashing lights are always operating when required.
The lights shall be operated during all the hours of darkness and also during daylight hours if specified in the Contract Documentation or by the
Engineer.
e) Warning flags
Flags shall be made from durable, bright red material and shall be square with a minimum side length of 600 mm. The flag shall be attached to a
flagpole staff at least 1,0 m in length. The warning flags shall be replaced whenever they become dirty or worn to the point where they are no
longer easily visible and effective.
f) LED strobe light wands
LED strobe light wands shall be hand held, battery powered LED wands with an amber lamp tube at least 200 mm in length which can be
operated in continuous or flashing mode.
A1.5.6.3 Traffic safety vehicle

The traffic safety vehicle to be used for transporting, placing, relocating and removing the traffic accommodation facilities and the traffic safety
devices shall be a truck with a load capacity of at least 5 tons fitted with:
• A high visibility rear panel in accordance with the requirements specified in the SARTSM.
• A rear mounted impact attenuation device which is capable of attenuating head-on impacts of at least Test Level TL2 (70 km/hr) in
accordance with AASHTO MASH, or NCHRP 350 where no MASH compliant product is available.
• An amber-coloured flashing LED light or light bar mounted on top of the roof of the cab, or on top of the rear canopy whichever is the
highest, which shall be clearly visible in daylight in all directions for a distance of at least 800 m. It shall be switched on continuously
while the vehicle is on site, is manoeuvring in or out of traffic or is travelling or parked alongside roads open to public traffic within the
work areas.
• A warning sign with the wording TRAFFIC CONTROL in retro-reflective Class 3 red letters at least 200 mm high on a retro-reflective
Class 3 white background, mounted in a visible position at the rear of the vehicle.
A1.5.6.4 Traffic safety officer’s vehicle

The traffic safety officer’s vehicle shall be provided for his sole use to enable him to carry out his supervisory duties.

The traffic safety officer’s vehicle shall both be equipped with the following:
• An amber-coloured flashing LED light or light bar mounted on top of the roof of the cab, or on top of the rear canopy whichever is the
highest, which shall be clearly visible in daylight in all directions for a distance of at least 800 m and it shall be switched on continuously
while the vehicle is on site, is manoeuvring in or out of traffic or is travelling or parked alongside roads open to public traffic within the
work areas.
• A warning sign with the wording TRAFFIC CONTROL in retro-reflective Class 3 red letters at least 200 mm high on a retro-reflective
Class 3 white background, mounted in a visible position at the rear of the vehicle.

A1.5.7.1 Accommodation of pedestrian traffic
The Contractor shall pay specific attention to the accommodation of pedestrian traffic wherever the safety of pedestrians could be compromised.
Safe, correctly marked and signposted pedestrian crossing points shall be provided at locations agreed to by the local community and the
Engineer to ensure that the pedestrians are safeguarded and shall be able to cross the site without being endangered. The pedestrians should
not be able to enter areas where Works are taking place.
Should a walkway be required, it shall have a clear opening of at least 1,2 m wide and 2,1 m high and shall be uniformly illuminated during
hours of darkness. The surface of the walkway shall be free from obstructions and shall be clearly signposted to guide the pedestrians towards
the walkway. If steps are required to reach the level of the walkway, these shall comply with the occupational health and safety requirements
and have proper handrails. No ramps shall be steeper than 1 (vertical) to 8 (horizontal).
Where specified by the Engineer a traffic safety meeting shall be organised to inform persons living in the local community about the safe use of
the designated pedestrian crossing points and to highlight all dangers associated with getting too close to the construction vehicles and
equipment.
A1.5.7.2 Accommodation of non-motorised traffic

In areas where non-motorised traffic is present, the Contractor shall ensure that there is sufficient width available to permit vehicles to pass the
slow moving non-motorised traffic safely. If this is not possible then the Contractor shall provide separate temporary deviations or alternative
detours to accommodate the non-motorised traffic.
A1.5.7.3 Accommodation of traffic where the road is constructed in half or partial widths
Where, for reasons related to traffic, geometric or other restraints, the provision of a detour, or the construction of a temporary deviation
alongside or in close proximity to the roadworks, is not possible or impracticable, the Contractor shall construct the Works on a half or partial
width of the existing road so as to allow public and construction traffic to use that remainder of the road surface which is currently not under
construction.
Half or partial width traffic accommodation shall be carried out in accordance with the requirements of this Section, any additional requirements
given in the Contract Documentation and any further written instructions issued by the Engineer. The specifications given in this section shall
also apply to a road that is being constructed in half or partial widths.
The length of the half or partial width construction sections where the traffic can only pass in one direction at a time shall not exceed the length
specified in the Contract Documentation. The number of one-ways sections under construction at any one time shall not exceed the number
permitted in the Contract Documentation and two-way traffic sections of at least 2.0 km in length shall be provided between each of the one-way
construction sections.
The start and end points of the half or partial width construction sections shall be as specified in the Contract Documentation or as decided on
site by the Engineer and confirmed to the Contractor in writing. All start and end points shall be positioned to ensure that there is sufficient traffic
queueing length before the traffic control point to ensure that oncoming traffic has a sufficient stopping sight distance as specified in Figure
13.25 given in Chapter 13 of Volume 2 of the SARTSM before the traffic queueing area.
The work zone and the one-way traffic lane shall be separated from each other by delineators and/or temporary barriers as specified in Volume
2 of the SARTSM and/or in the Contract Documentation and by the Engineer where applicable.
The Contractor shall maintain the portion of the road which is being used to accommodate the traffic in a safe, clean and trafficable condition at
all times.
The one-way traffic shall be controlled by a STOP / GO system manned by an adequate number of traffic controllers, flagmen and/or traffic
signals, signs, barricades, lights and the necessary supervisory staff to ensure a reasonably free flow of traffic alternately in each direction
throughout the entire period when the roadway is open to one-way traffic only.
Whenever the one-way STOP / GO system is operation during hours of darkness the use of traffic signals to control the traffic in addition to the
traffic controllers shall be compulsory. Flashing amber lights shall be mounted on top of the initial advance warning signs (usually positioned 1,0
km before the control point) and the traffic stopping and queueing length areas shall be illuminated with pole mounted floodlights.
The Contractor shall programme the Works in such a way to ensure that there are no STOP / GO one-way traffic sections in operation and that
two-way traffic can be accommodated safely within the contract limits during the Contractor’s annual shutdown period between December and
January or during any other shutdown periods which may be specified in the Contract Documentation. The Contractor shall endeavour to ensure
that there is no vertical step between two opposing traffic lanes during a shutdown period. If a step between opposing traffic lanes is
unavoidable then delineators or barriers shall be erected between the opposing traffic lanes as specified in the Contract Documentation or as
instructed by the Engineer. These traffic accommodation measures must be maintained by the traffic safety personnel for the full duration of the
shutdown period,
The Contractor shall programme his work taking due cognizance of all restrictive conditions associated with accommodating the traffic in half or
partial width construction sections.
A1.5.7.4 Crossing the median or the road centreline

All entry, exit and turning points on a single or dual carriageway road should be at existing intersections wherever possible. Where not possible
all access points shall be located at safe points which have been planned in advance and agreed with the Engineer. They shall only be located
at points where there is sufficient sight distance at least 300 m in a 60 km/hr construction zone or temporary detour, 400 m on a road with an 80

km/hr posted speed limit, 500 m on a road with a 100 km/hr posted speed limit and 600 m on a road with a 120 km/hr posted speed limit. They
shall be well signposted with advance heavy vehicle turning warning signs and speed limit restriction signs in accordance with the requirements
given in the South African Road Traffic Signs Manual.
No vehicles belonging to the Contractor or the Engineer’s staff and no construction equipment shall be allowed to cross the median of a dual
carriageway road. Approved access points shall always be used by all vehicles and construction equipment.
No vehicles belonging to the Contractor or the Engineer’s staff and no construction equipment shall be allowed to cross the centreline of a single
carriageway road unless the traffic accommodation arrangements, road markings and signage specifically allows for this.
A1.5.7.5 Display of existing permanent signs

The Contractor shall adhere strictly to the sign layout and spacing specified in Chapter 13 of Volume 2 of the SARTSM, specified in the Contract
Documentation or as directed by the Engineer. Any sign not required, or which is in contradiction with the prevailing situation, shall be removed
to storage or covered with a non-transparent, weather proof and durable cover without delay.
The covers shall be in the form of a sack made from a durable, opaque material with a drawstring or ties at the open end so that the cover may
be placed over the sign and fastened in position. The use of thin plastic bags or a single layer of material taped over the front of the sign will not
be permitted.
The Contractor shall be responsible for the care and maintenance of all existing permanent signs and take the necessary precautions to prevent
them from being scratched or damaged in any way. Any permanent signs that are scratched or damaged by the Contractor’s staff and/or
vehicles or equipment shall be replaced by the Contractor as his own cost.
A1.5.7.6 Maintenance of existing roads used as detours

Where specified in the Contract Documentation, all existing roads used as detours by public traffic, and/or by the Contractor’s vehicles, for
bypassing the Site of the Works shall be maintained by the Contractor in a good and safe trafficable condition for the entire period during which
such roads are used as detours.
Maintenance of these roads used as detours shall include grass cutting, removal of rubbish, cleaning of all drains and culverts and repair of
potholes and surface failures as instructed by the Engineer. Unless otherwise specified in the Contract Documentation the maintenance work
shall also include the care and maintenance of all road markings, road signs, delineators and guardrails.
A1.5.7.7 Liaison with traffic authorities

The Contractor shall liaise with the relevant provincial and/or municipal traffic authority, and with the Employer’s traffic management centre if
applicable, at the start of the contract period and as often as required thereafter to keep them continually informed in advance about the
expected Works being carried out and the detour and deviation and lane closure arrangements that will be in place.
A daily report covering the expected work and traffic control arrangements for the following day shall be submitted to the relevant traffic
authorities or to the traffic management centre not later than 10h00.
For exceptional traffic accommodation impacts, such as lane closures in peak hours, short term contra flow conditions, lane closures over
weekend peak periods etc., the relevant traffic authorities, and the Employer’s traffic management centre if applicable, shall be informed seven
days prior to the event.
The Contractor shall inform the relevant traffic authorities, and the Employer’s traffic management centre if applicable, about all traffic related
incidents as soon as he becomes aware of the incident. The Contractor’s site agent and his traffic safety officer must always have the relevant
telephone numbers and email addresses with them so that contact can be made as soon as any traffic related incidents occur.
The Contractor shall, in appropriate circumstances that have been agreed with the relevant provincial and/or municipal traffic authorities, be
responsible for acquiring the services of a provincial or municipal traffic officer and traffic vehicle (equipped with a blue light) to assist in the
accommodation of traffic. The traffic officer and traffic vehicle will be required when lanes are to be closed, or where directed by the Engineer.
If the road under construction forms part of an abnormal load route the Contractor shall liaise with the relevant provincial abnormal load office
that issues permits to ensure that permits are not issued when horizontal and/or vertical restrictions do not allow passage of the abnormal load.
A1.5.7.8 Informing the road users

The Contractor shall on a continual basis, and at least one week prior to a major event, inform the road users of the intended road Works,
construction period and accommodation of traffic arrangements through press releases in local and provincial newspapers and via local radio
channels.
Any temporary road closures required for blasting operations, or for any other reason, shall also be advertised on sign boards erected in
appropriate positions along the section of road to be closed at least fourteen calendar days prior to each closure.
A1.5.7.9 Lighting of construction access points during night work

Where work is required to be done during the night the Contractor shall make adequate provision for additional lighting to ensure that all vehicle
and equipment entry and exit points are adequately lighted. The Contractor shall provide floodlights to ensure that a minimum 200 lux lighting
level is provided at all these areas.
The floodlights must be mounted on masts at least 9m high to ensure that they illuminate the required areas without being directed into the
vision of oncoming drivers.
A1.5.7.10 Construction of temporary deviations

a) General
Unless otherwise specified in the Contract Documentation, or instructed by the Engineer in writing, the construction of temporary deviations
shall be done in conformance with the requirements and specifications given in this section as well as in other relevant chapters of this Standard
Specification as follows:
• Clearing and grubbing – Chapter 1, Section A1.6
• Drainage – Chapter 3.

• Earthworks and pavement layers – Chapters 4 and 5.
• Asphalt surfacing – Chapter 9.
• Bituminous surfacing – Chapter 10.
• Ancillary road works – Chapter 11.
The proposed location and layout of all temporary deviations, including the signage required, shall be agreed with the Engineer before
construction of the temporary deviation commences.
b) Drainage works for temporary deviations
The Contractor shall construct the necessary temporary drainage works such as side drains, catch-water drains, mitre drains, culverts, etc., to
deal adequately with any storm water and surface water run-off.
Temporary culverts of the type and size specified by the Engineer shall be installed on existing drainage channels. Any suitable prefabricated
culverts salvaged from an existing road or an abandoned temporary deviation may be re-used if they are in a good condition and are accepted
by the Engineer.
All drainage works shall be maintained in a clean condition and in good working order.
Any flood damage caused to a temporary deviation shall be repaired by the Contractor as soon as the flood water has subsided.
c) Earthworks for temporary deviations
The Contractor shall perform the necessary clearing and grubbing, including the removal of all trees and stumps. The Contractor shall then
shape and grade the temporary deviation and prepare the roadbed.
The Contractor shall make full use of all suitable material that can be obtained from alongside the temporary deviation, from side cuts or from
the immediate vicinity for the construction of any fills that are required. If an adequate quantity of acceptable fill material cannot be obtained in
this manner it shall be imported from other approved sources. Where necessary, cuttings shall be made to obtain additional fill material and/or to
achieve a satisfactory vertical alignment.
The earthworks across stream crossings shall be constructed from rock fill or coarse material so as to limit, in so far as is possible, damage
caused by flood water.
d) Earthworks and pavement layers for temporary deviations
The Contractor shall provide the fill and pavement layers required for the temporary deviations in accordance with the requirements specified in
the Contract Documentation or as instructed by the Engineer.
The cross fall shall be maintained between 3 % and 4 % on gravel deviations and between 2 % and 3 % on surfaced deviations.
If existing gravel shoulders are to be used for the accommodation of traffic and they are unsafe and/or not wide enough, the shoulders shall be
reconstructed. All grass and unsuitable material shall be bladed from the surface and, where necessary, roadbed preparation shall be done.
Additional wearing course gravel material shall be imported from the road reserve or from borrow pits as required to provide a layer of wearing
course gravel at least 150 mm thick after compaction. The gravel shall then be placed and compacted as specified in the Contract
Documentation.
e) Surfacing of temporary deviations
The Contractor shall surface the temporary deviations in accordance with the requirements specified in the Contract Documentation or as
instructed by the Engineer.
Unless otherwise specified in the Contract Documentation, or instructed by the Engineer, the surfaced width of a temporary deviation
accommodating two-way traffic shall be 8,5 m to provide two 3,5 m wide traffic lanes with a 0,75 m wide surfaced shoulder on each side. A
further 0.75 m wide gravel shoulder shall also be provided on each side to provide a minimum total roadway width of 10,0 m. Where temporary
deviations consist of two separate one-way lanes, the minimum surfaced width of each lane shall be 3,5 m. A further 0,5 m wide gravel or
surfaced shoulder shall also be provided on each side to provide a minimum total roadway width of 4,5 m in each direction.
f) Maintenance of temporary deviations
All temporary deviations shall be maintained by the Contractor in a safe trafficable condition at all times.
All potholes and surface failures shall be repaired as soon as possible. The Engineer may also instruct the Contractor to resurface the
temporary deviation or existing road being used as a detour if it becomes necessary.
Whenever required by the Engineer, temporary gravel deviations shall be bladed by means of self-propelled road graders to provide a smooth
riding surface free from corrugations. The Engineer may also instruct the Contractor to water the temporary gravel deviations to keep down dust
or to facilitate the proper blading of the surface.
g) Removal of temporary deviations
After traffic is rerouted permanently onto the new road, and on the written instructions of the Engineer, the Contractor shall remove temporary
deviations. All roadwork materials, drainage structures, temporary signage, barricades and guardrails etc. will be removed either to spoil or to
temporary storage for re-use elsewhere in the Works.
All temporary signage and road markings on the approaches to the temporary deviations shall also be removed.
A1.5.7.11 Temporary traffic control facilities

a) General
The Contractor shall provide, erect and maintain the necessary temporary traffic-control facilities, which are comprised of traffic control devices,
road signs, channelization devices, barricades, warning devices and road markings, in accordance with the specifications given in Chapter 13 of
Volume 2 of the SARTSM, in this Section or as specified in the Contract Documentation. The details shown for spacing and placement of traffic-
control facilities may also be revised by the Engineer in writing where deemed necessary to accommodate local site geometry and traffic
conditions.

The Contractor shall ensure that all the temporary traffic control facilities devices are present where required at all times and are always
functioning properly.
Traffic control facilities no longer required at a particular site shall be moved and stored safely for re-use.
All traffic control facilities which are scratched, bent, broken or otherwise damaged by the Contractor’s staff and/or vehicles, construction
equipment or by any other road users to the point where the Engineer considers them to be no longer usable or compliant shall be replaced by
the Contractor at his own cost if they were not:
• Carefully stored, handled or transported.
• Correctly attached to their support bases, poles or frames.
• Correctly erected or ballasted.
• Erected in the correct position and/or not maintained in their correct position which made them likely to be damaged by passing
vehicles.
If, due to poor storage, handling, transportation or old age, the co-efficient of retro-reflection of any of the signs fall below 80% of the value
specified in the current edition of SANS 1519-1 for the grade and colour of the material used, the sign shall be considered defective and it shall
be replaced at the Contractor’s own cost.
All correctly erected, ballasted and positioned temporary traffic control facilities which are damaged by public road users shall be replaced and
paid for under the relevant payment item.
All lost or damaged items shall be replaced as soon as possible within a maximum period of two hours of the Contractor becoming aware of it or
of receiving instructions from the Engineer.
b) Channelization devices
Channelization devices may consist of either delineators or traffic cones or a combination of both as specified in the Contract Documentation.
The use of drums as channelization devices shall not be permitted.
Delineators shall be placed at the spacing specified in the Contract Documentation. They shall be positioned with the reflective chevron facing
the oncoming traffic to indicate the side of the road or deviation on which the vehicles should travel.
Traffic cones may only be used only at short deviations where both ends of the deviation are visible to the drivers of the approaching vehicles.
They may only be used in conjunction with flagmen stationed at each end of the deviation. If the length of the deviation exceeds 100 m then
cones shall not be used on their own but shall be interspersed with delineators at a ratio not exceeding 3:1 and, if considered necessary by the
traffic safety officer and/or the Engineer, additional flagmen shall be stationed where the work is taking place.
Traffic cones may only be used during daylight hours. Deviations and lane closures which are still in place at sunset shall be demarcated with
reflective delineators only.
Where traffic is being accommodated on new sections of road where no road markings have yet been painted, double sided reflective
delineators shall be erected along the centre line of two way roads at a spacing not exceeding 20m. Delineators shall also be placed along the
outer edges of the surfaced roadway at a spacing not exceeding 80 m on straight sections of the road and 40m around curves in the road.
Alternatively, the Engineer may request or permit the use of temporary road studs where appropriate.
c) Erection of temporary vehicle restraint systems
Before ordering and erecting any temporary vehicle restraint systems the Contractor shall first take cognisance of his liabilities relating to the
installation of temporary works to provide protection to the permanent Works and to ensure the safety to his personnel before he selects a
vehicle restraint system appropriate to his chosen work methodology. Particularly pertinent is the working width rating of the vehicle restraint
system as the displacement width of the system shall not exceed the available safe width to the nearest edge of the construction area. All
vehicle restraint systems shall be installed and connected in accordance with the manufacturer's instructions and shall be submitted to the
Engineer for review and comment.
If the Employer makes his own temporary vehicle restraint system available for the Contractor to use, no transfer of responsibility for use of that
system shall pass to the Employer. The Contractor shall retain the responsibility for ensuring that the barrier system provided by the Employer
provides an adequate and appropriate level of protection. Before deciding to make use of the Employer’s vehicle restraint system the Contractor
shall obtain full details of the system and the approved connecting system to confirm and satisfy himself that the system is compliant with one or
both of the two international specifications specified in Clause A1.5.6.1a) and to confirm that the working safe working width classifications
behind the barriers for the various vehicle classes and impact characteristics are compliant with the requirements of the construction section
where the vehicle restraint system will be installed.
d) Cleaning of traffic control facilities
All road signs, delineators, traffic cones, flashing arrow boards, illuminated signs, variable message boards and the reflectors on vehicle
restraint systems and guardrails shall be cleaned at least once a week or more often if they are in a position where they are splashed with dirt
by passing traffic and/or construction vehicles. All dust, mud, concrete, bituminous or other foreign material shall be cleaned off.
e) Flagmen and traffic controllers
Flagmen shall be provided at the positions specified in the Volume 2 of the SARTSM or specified in the Contract Documentation. These
positions may be varied to suit local geographic or traffic conditions if so instructed by the Engineer. Flagmen shall also be positioned in
advance of all work zone construction vehicle exit points to control construction vehicles re-entering the trafficked lane/s.
During the daytime, at least one flagmen shall be provided at each traffic control point in addition to the STOP/GO sign and/or traffic signal
operator. One flagman shall also be positioned at the first speed reduction sign and a second roving flagman shall be positioned at least a 100m
behind the last vehicle in the queue at STOP/GO points to warn the oncoming traffic to stop. Additional flagmen shall be positioned at least
100m in advance of any possible traffic conflict points such as lane closures and lane drops.
The number of flagmen and traffic controllers to be employed each day shall be agreed with the Engineer at the commencement of the Works
and thereafter whenever the numbers required on site change. Flagmen and traffic controllers shall not work for periods exceeding four hours
without being given a rest period of at least one hour and sufficient additional flagmen and traffic controllers shall be available to relieve them as
required.

All flagmen and traffic controllers shall be provided with conspicuous orange or bright yellow clothing as well as approved safety vests/jackets
utilizing retro-reflective and/or fluorescent panels in red, yellow, white and/or silver. The clothing and/or the safety vests/ jackets must be kept
clean and they shall be replaced by the Contractor at his own cost when they are no longer in good condition.
During hours of daylight all flagmen and traffic controllers shall be equipped with a red warning flag as specified in Clause A1.5.6.2e).
During hours of darkness all flagmen and traffic controllers shall be equipped with an amber LED strobe light wand as specified in Clause
A1.5.6.2f).
No flagman or traffic controller shall work on site longer than one 8 hour shift per day. Including transport to and from work no flagman or traffic
controller should be on duty for a period of more than 10 hours per day.
Flagmen shall be adequately trained in the standard flagging techniques as described in Volume 2 of the SARTSM. Flagmen shall have in their
possession at all times a certificate showing that they have attended training provided by an accredited training company.
In terms of lateral clearance and safety, flagmen and traffic controllers shall stand on the shoulder of the lane of traffic that is being controlled
and shall not be permitted to stand within the traffic lane.
The traffic controllers and any flagmen acting as STOP / GO controllers shall have an approved two-way communication system if they are not
within an easily visible signalling distance of each other.
f) Temporary road markings and road studs
Temporary road markings may be required on bituminous and concrete surfaces. The road markings shall normally be applied using retro-
reflective road marking paint in accordance with the specifications given in Section A11.7 of Chapter 11. However, in some instances, the
temporary road markings may consist only of, or a combination of, heavy pre-marking, temporary road studs and reflective road marking tape.
as directed by the Engineer.
Temporary road studs shall be fixed to the road surface with a flexible bitumen rubber sealant material, as opposed to an epoxy adhesive, for
easy removal by application of low heat.
Temporary road markings shall not be painted onto to the final, new road surface except where instructed by the Engineer. Where possible,
reflective road marking tape, capable of being easily removed from the road surface by the application of low heat, shall be used for any
temporary road markings required on a new road surface. Should temporary road marking be approved but require removal, they shall be
removed, when no longer required, only by means of sandblasting or water jetting. Covering existing road marking with black paint will not be
allowed under any circumstances.
g) Temporary road signs
All temporary road signs that are required to remain in position for some time shall be pole mounted as for permanent signs in the positions
shown on the drawings. All temporary road signs that need to be moved more often shall be mounted on portable support frames which are
designed to support the signs in a stable, upright position. The signs may not be displayed with their sign faces more than 20O off the vertical
plane. (i.e. a maximum slope of 1 horizontal to 3 vertical will be permitted).
The only permitted method of ballasting the temporary road sign support frames shall consist of durable sandbags filled with clean, fine sand of
adequate mass to prevent the signs from being blown over by passing heavy vehicles travelling at speeds of up to 80 km/hr or by gusting wind
with wind speeds of up to 60 km/hr. The filling of sandbags with stone of size greater than 2mm shall not be permitted.
h) Traffic calming devices
Traffic calming devices will be installed in positions as specified in the Contract Documentation or as instructed by the Engineer. These devices
may include rumble strips, rumble humps or speed reduction humps / bumps that shall conform to the dimensions and specifications given in
If any of these traffic calming devices are used, then temporary advance warning signs shall be erected in accordance with the specifications of
the SARTSM. If the Engineer considers it necessary, the warning signs shall be supplemented with flagmen to warn motorists of the presence of
the temporary traffic calming devices.
Movable variable message signs warning the traffic of the required speed limit, the actual speed being travelled and/or a message telling the
driver to slow down may also be used as traffic calming devices if specified in the Contract Documentation or instructed by the Engineer.
i) Traffic control measures
Traffic control measures shall be provided at either end of all deviations and at all side roads within the deviation. The traffic control points may
comprise any of the following and shall be provided / used as specified below.
Day time traffic control for short deviations
Flagmen with STOP/GO signs may be used to control traffic over short deviations where both ends of the deviation are visible to the drivers of
the approaching vehicles. The flagmen operating the STOP/GO signs must have an effective communication system if they are not within an
easily visible signalling distance of each other they shall be equipped with an effective communication system.
No such day time closures shall be permitted during hours of darkness and the Contractor shall ensure that he completes the required work and
reopens the road to traffic before nightfall.
Day time traffic control for long deviations
On long deviations where both ends of the deviation are not visible to the drivers of the approaching vehicles moveable barriers, fitted with a
STOP sign facing the oncoming traffic, shall be provided at the traffic control point to prevent vehicles from utilising the closed road lanes. These
barriers shall be moved by the traffic controller to open and close the relevant lanes for road users as required.
Each traffic controller shall be provided with an effective communication system that allows the controllers to communicate with each other in
order to coordinate and control the one-way traffic safely and efficiently. Records of the time period and the number of vehicles going through
shall be kept at each traffic control point and submitted daily to the traffic safety officer who shall submit a copy of these records to the Engineer.
Night time traffic control
The Contractor shall provide traffic control stations manned by trained traffic controllers as specified in Clause A1.5.6.1f) for all deviations which
are used during the hours of darkness.

Records of the number of vehicles going through during each shift period shall be kept at each traffic control point and submitted daily to the
traffic safety officer who shall submit a copy of these records to the Engineer.
Traffic control on side roads
The Contractor shall provide a traffic controller equipped with a STOP/GO sign at the intersection of all side roads that fall within a one-way
deviation. The traffic controller shall have an effective method of communication with the traffic controllers at either end of the deviation to
enable him to control any vehicles entering from the side roads to ensure that they do not travel against any oncoming traffic.
A1.5.7.12 Traffic safety officer

The Contractor shall appoint a knowledgeable, experienced and conscientious person as his traffic safety officer who shall be responsible for
the arrangements and maintenance of all accommodation of traffic measures required for the duration of the contract. The Contractor shall
submit details of the person’s qualifications, training and experience to the Engineer for comment before appointing him.
The traffic safety officer shall be able to communicate in the languages of the area and shall be a dedicated official who shall have no other
responsibilities on site unless permitted otherwise on small projects in the Contract Documentation or by the Engineer.
The traffic safety officer shall be equipped with a dedicated vehicle and a cellular telephone and shall have sufficient labour and a Traffic Safety
Vehicle, as specified in Clause A1.5.6.2, at his disposal 24 hours a day.
The traffic safety officer shall always have a direct line of communication with the police and traffic officers responsible for the area within limits
of the contract and shall be responsible for maintaining liaison with them in accordance with the requirements given in Clause A1.5.7.7.
The traffic safety officer will be required to perform the following duties and this list shall not be deemed to be comprehensive. He shall:
• Ensure that all the Contractor’s personnel, all the Engineer’s site staff and all visitors are wearing approved, clean safety jackets utilizing
retro-reflective and/or fluorescent panels in red, yellow and/or white when they are on the site of the Works.
• Make himself available to discuss road safety and traffic accommodation matters whenever required by the Engineer and shall be
responsible for keeping the temporary traffic accommodation requirements up to specification 24 hours a day 7 days a week.
• Set out and record the position of each sign, barricade, delineator, cone, amber flicker light, guardrail and permanent or temporary
painted road marking feature and every other traffic control facility for each closure or temporary deviation as specified on the drawings
and Contract Documentation. The position of each facility shall be adequately referenced from the marker boards or other surveyed
points on the site of the Works. These records shall also show the date and time at which the recorded traffic accommodation features
are certified as correctly positioned and erected by the Traffic Safety Officer, and shall be signed by him before being submitted to the
Engineer.
• Take digital photographs and/or video footage covering the full extent of the temporary traffic accommodation arrangements on the site
of the Works whenever any new arrangements are made. The digital photographs / video footage shall be submitted to the Engineer in
electronic format for his records.
• Inspect the position and condition of each traffic accommodation feature on the whole site of Works twice per work shift, once before the
start of the morning and evening peak traffic periods and again during the middle of the work shift if both day and night shifts are in
operation.
• Record all irregularities discovered and the remedial action taken and then date and sign the record sheets off as correct and submit
copies to the Engineer by 10h00 the following working day. The above inspections must at least take place before the commencement
of peak traffic periods.
• Collate and submit the daily labour returns of flagmen, stop/go, and traffic signal control personnel employed and the open/close periods
and traffic count data recorded at each traffic control point to the Engineer each morning.
• Exercise control in terms of traffic safety over the safe movement of personnel, visitors and plant on site including the wearing of high
visibility clothing, safety jackets, the operation of amber flashing lights and the display and cleanliness of "Construction Vehicle" signs,
all as specified.
• Ensure that all road signs, delineators, barrier reflectors and traffic cones are always kept clean and visible as specified in Clause
A1.5.7.11d).
• Attend to the training and performance of flagmen and all other personnel involved in the control of traffic.
• Attend to all complaints and claims from the public with respect to traffic safety and report on such matters to the Engineer.
• Ensure that all obstructions that are caused by Contractor’s vehicles, equipment, materials and tools or other objects related to the work
activities are removed out of and away from the trafficked area, or suitably barricaded off as specified, so that the roads are safe to use
by the travelling public.
• Arrange for the removal of stationary or broken down vehicles off the roadway in conjunction with the traffic authorities.
In the event of an accident within the Site of the Works, the traffic safety officer shall implement any actions requested by the traffic authorities
with respect to the work to be carried out and he shall be responsible for the erection and maintenance of all traffic signs necessary for the
accommodation of traffic. He shall record in a written report the details of the accident and record the position of all temporary road signs,
barricades, delineators, flagmen and any other devices used for traffic accommodation. The report shall include a neat, accurate dimensional
sketch, photographs and notes about any identifiable permanent features related to the accident, together with any other relevant information.
As soon as it is available he shall obtain the accident case number from the traffic authorities and attach it to the report before submitting a copy
of the report to the Engineer for his records.
A1.5.7.13 Towing of public vehicles

If specified in the Contract Documentation, the Contractor shall arrange for tow trucks to be on call for removing broken down light and/or heavy
vehicles for the duration specified in the Contract Documentation.
Payment for towing trucks off the road and/or on to a storage or repair facility will not be made as this cost is to be recouped from the owner of
the towed vehicle.

A1.5.8 WORKMANSHIP
The Contractor shall implement a process control system which shall ensure that all traffic control facilities and signs are erected in the correct
position and are regularly maintained and kept clean.
The Contractor’s process control system shall also ensure that all safety personnel are correctly trained and that they are carrying out their
duties correctly.

B1.5 ACCOMMODATION OF TRAFFIC
CONTENTS
B1.5.1 SCOPE
B1.5.2 DEFINITIONS
B1.5.3 GENERAL
B1.5.5 MATERIALS

B1.5.8 WORKMANSHIP
B1.5.1 SCOPE
The nature of the work required to accommodate the traffic is labour intensive and no additional labour enhancement requirements are specified
for Section A1.5.
B1.5.2 DEFINITIONS
Clauses B1.5.3.to B1.5.8 are not applicable to this Section.

C1.5 ACCOMMODATION OF TRAFFIC
(i) Preamble
otherwise stated.
Any prime cost or provisional sums shall be paid in accordance with the provisions of the conditions of contract. The charge or mark-up
deemed appropriate:
1. Removal of any material that is driven onto or spilt on any temporary roads, public roads or privately owned roads that are being used to
accommodate traffic during the haul of material or while any construction operations are being carried out.
2. The provision of lighting for construction access and exit points during night work. All costs related to illuminating the area of the access
and exit points at night, as specified in Clause A1.5.7.9, shall be included in the relevant payment items applicable to the work being
carried out at night.
3. The provision of the flashing amber lights / light bars and “Construction Vehicle” warning boards which shall be fitted to the Contractor’s
vehicles and construction equipment. All costs related to the provision of these warning devices shall be included in the relevant payment
items applicable to the work being carried out.
4. The provision of safety clothing, warning flags and amber LED strobe light wands for traffic safety officers, flagmen and traffic controllers;
the cost of these shall be included in the rate for providing these personnel.
5. The cleaning, repair or replacement of any traffic control facilities damaged by the Contractor’s staff and/or vehicles and construction
equipment or were dirtied / damaged because they were:
− not correctly stored, handled or transported,
− not correctly attached to their support bases, poles or frames,
− not correctly erected or ballasted OR
− erected in the incorrect position and/or not maintained in their correct position which made them likely to be damaged by passing
vehicles.
6. The replacement of any traffic control facilities that are stolen from the Site of the Works. (All traffic control facilities provided on the Site of
the Works shall be covered by the Contractor’s insurances or by the Contractor should he elect not to insure them.)
For activities shown in Table C1.5-1 payment items specified in other Chapters or Sections of the specifications, where they relate to work under
this Section, will be listed in the Pricing Schedule.
Identification, protection and relocation of existing services A1.5.3.11 C2.1.1 & C2.1.2 of Chapter 2
Chapters 1, 3, 4, 5, 9 & 10 - All

Temporary deviations A1.5.5.1
relevant pay items as applicable
C3.2.1 to C3.2.24 of Chapter 3 as
Temporary culverts A1.5.5.2
applicable
C11.4.1 to C11.4.15 of Chapter 11
Temporary road restraint systems A1.5.5.3 & A1.5.6.1(a)
as applicable
C11.5.1 to C11.5.10 of Chapter 11
Temporary fencing and gates A1.5.5.4
as applicable
C11.6.1.8, C11.6.1.10,
C11.6.1.12, C11.6.2, C11.6.3,
Temporary road signs and removal, storage, covering and
A1.5.5.5 & A1.5.6.1(c) C11.6.5, C11.6.6. C11.6.7
re-erection of existing road signs
& C11.6.10 of Chapter 11 as
applicable
C11.7.1 to C11.7.10 of Chapter 11
Temporary road markings and road studs A1.5.5.6
as applicable

(iv) Items specifically for this section of the Specifications
C1.5.1 Accommodation of pedestrian and non-motorised traffic
C1.5.1.1 Accommodation of pedestrian and non-motorised traffic month
C1.5.1.2 Construction of temporary pedestrian walkways and/or cycle paths:
(a) Gravel surfaced pedestrian walkways / cycle paths square metre (m2)
(b) Bitumen surfaced pedestrian walkways / cycle paths square metre (m2)
(c) 60 mm concrete block paved pedestrian walkways / cycle paths square metre (m2)
The unit of measurement for item C1.5.1.1 shall be the month or part thereof that the accommodation of pedestrian and/or non-motorised traffic
is required on site during the approved Contract Period. No distinction will be made with respect to the type and/or number of pedestrian
crossings, walkways and cycle paths required.
The contract rate for item C1.5.1.1 shall include full compensation for the costs of complying with all the general obligations of the Contractor,
including keeping pedestrians and non-motorised traffic informed of the accommodation arrangements and facilities, for the costs of placing,
maintaining and relocating temporary signage and all other traffic control facilities as often as required and for any other related costs that are not
covered by, or included in, the other items given below.
The unit of measurement for items C1.5.1.2(a), (b) and (c) shall be the square metre of temporary pedestrian walkways and/or cycle paths
constructed as specified in the Contract Documentation. The contract rate shall include full compensation for all design and supervision costs
together with any other general costs associated with providing the temporary pedestrian walkways and/or cycle paths. It shall also include full
compensation for the cost of constructing and later removing the walkways and/or cycle paths when they are no longer required.
All loading and hauling of material required, for the construction of walkways and cycle paths shall be included in the contract rates.
C1.5.2 Accommodation of vehicular traffic month
The unit of measurement for item C1.5.2 shall be the month or part thereof that the accommodation of vehicular traffic is required on site during
the approved Contract Period. No distinction will be made with respect to the type and/or number of detours, deviations or partial / half width road
sections used to accommodate the traffic. The contract rate for item C1.5.2 shall include full compensation for complying with all the general
obligations of the Contractor, including keeping motorists informed of the traffic accommodation arrangements and facilities, for the costs of
placing, maintaining, relocating and protecting from damage all temporary and permanent signage and all other traffic control facilities as often as
required for constructing the Works and for carrying out testing and inspections and for any other related costs that are not covered by, or
included in, the other items given below.
C1.5.3 Liaison with traffic authorities month
The unit of measurement shall be the month or part thereof that the liaison with the traffic authorities, or the Employer’s traffic control centre, is
required on site, regardless of the frequency of liaison that is required during each month during the approved Contract Period.
The contract rate for item C1.5.4 shall include full compensation for all the Contractor’s costs incurred while complying with all the requirements
specified in Clause C1.5.7.7.
C1.5.4 Construction of temporary deviations
The applicable payment items required for the construction of temporary deviations shall be
taken from the relevant chapters and sections in Chapters 1, 3, 5, 9 and 10 and inserted into
the Pricing Schedule here. Each payment item for the construction of temporary deviations
shall be preceded by the main payment item number C1.5.4 / followed by the payment
number for the applicable payment item.
The unit of measurement for each item shall be as specified in the relevant payment item given in the applicable section of the pricing schedule.
The contract rates for these items shall include full compensation for the construction of temporary deviations or the repair / upgrading of detours
as specified in the relevant section of these Specifications.

C1.5.5 Maintenance of temporary deviations
C1.5.5.1 Grass cutting hectare (ha)
C1 5.5.2 Drain cleaning kilometre (km)
C1.5.5.3 Cleaning out culverts cubic metre (m3)
C1.5.5.4 Collection of rubbish / litter kilometre (km)
C1.5.5.5 Base patching using crushed stone material stabilised with bitumen emulsion and cement cubic metre (m3)
C1.5.5.6 Base and/or surface patching using cold premixed asphalt kilogram (kg)
C1.5.5.7 Base and/or surface patching using hot plant mixed asphalt tonne (t)

C1.5.5.8 Replacement of damaged guardrails metre (m)
C1.5.5.9 Grading of temporary deviations and existing roads used as detours kilometre (km)
C1.5.5.10 Watering of temporary deviations and existing roads used as detours kilolitre (kl)
C1.5.5.11 Other road maintenance work ordered by the Engineer provisional sum
Payment will only be made under items C1.5.5.1 to C1.5.5.12 when the relevant item of maintenance work has been ordered by the Engineer in
writing and the Engineer has confirmed in writing the scope, quantity and/or frequency of work that is to be carried out.
The unit of measurement for item C1.5.5.1 shall be the hectare. The contract rate shall include full compensation for cutting grass in restricted
and steep access areas with hand tools in addition to mowing grass in more accessible areas.
The unit of measurement for items C1.5.5.2 shall be the kilometre of side or median drain cleaned. Each drain shall be measured separately.
The contract rate shall include full compensation for the removal of all silt, mud, gravel, rocks and any other obstructions in the drain as well as
for loading and hauling the removed material to spoil regardless of the haul distance.
The unit of measurement for item C1.5.5.3 shall be the cubic metre. The contract rate shall include full compensation for the removal of all silt,
mud, gravel, rocks and any other obstructions from inside the culvert or from the culvert entrance and exit as well as for loading and hauling the
removed material to spoil regardless of the haul distance.
The unit of measurement for item C1.5.5.4 shall be the kilometre measured along the centreline of the temporary deviation. The contract rate
shall include full compensation for collecting all the rubbish / litter alongside the temporary deviation and carting it to an approved disposal site
regardless of the haul distance.
The unit of measurement for items C1.5.5.5, C1.5.5.6 and C1.5.5.7 shall be the cubic metre, kilogramme and tonne respectively. The contract
rates shall include full compensation for excavating the failed area of the temporary deviation to the depth indicated by the Engineer, cleaning out
and squaring off the excavation, priming the compacted surface or the floor of the excavation, and the sides of the excavation as applicable, and
then backfilling the excavation as specified in the Contract Documentation. The contract rates shall also include full compensation for all final site
cleaning and removal to spoil of all surplus material regardless of the haul distance.
The unit of measurement for item C1.5.5.8 shall be the linear metre of guardrail replaced. The contract rate shall include full compensation for
removing the damaged guardrails to spoil or storage as specified by the Engineer, reinstating or replacing any displaced or damaged guardrail
posts and providing and installing a new guardrail in the correct position.
The unit of measurement for item C1.5.5.9 shall be the kilometre of gravel surfaced temporary deviation which is graded smooth with a motor
grading to remove all corrugations and to redistribute the bladed gravel material evenly across the road surface. The contract rate per kilometre
shall include full compensation for providing and maintaining the motor grader and grading the road surface to restore the riding quality as
specified in the Contract Documentation, regardless of any variations in the width of roadway being graded.
The unit of measurement for item C1.5.5.10 shall be the kilolitre of water sprayed on the surface of temporary deviations as and when instructed
by the Engineer in writing. The contract rate shall include full compensation for providing, transporting and spraying the water on the road
surface.
The provisional sum allowed under item C1.5.5.11 shall provide for all other maintenance work carried out by the Contractor on the temporary
deviations that may be required as specified in the Contract Documentation or as ordered by the Engineer. The provisional sum shall be paid in
accordance with the provisions given in the Contract Documentation. Where applicable existing contract rates or accepted day work rates will be
used.
The percentage under item C1.5.5.12 is a percentage of the amount spent under item C1.5.5.11 which shall include full compensation for all
handling costs, profit and all other charges in connection with arranging and carrying out the maintenance works.
C1.5.6 Removal of temporary deviations kilometre (km)
The unit of measurement for item C1.5.6 shall be the kilometre. The contract rate shall include full compensation for removing temporary
deviations as specified in Clause A1.5.7.10g). The contract rate shall include for all removal, loading and hauling operations required regardless
of the haul distance.
C1.5.7 Temporary traffic control facilities
C1.5.7.1 Delineators including mounting bases and ballast:
(a) Single sided, reversible left or right (size indicated) number (No)
(b) Double sided, reversible left or right (size indicated) number (No)
C1.5.7.2 Traffic cones, minimum height 750 mm number (No)
C1.5.7.3 Flagmen man-shift
C1.5.7.4 Traffic controllers man-shift
C1.5.7.5 Provision of illuminated traffic signs:
(a) Sign mounted flashing amber lights (2 lights with the specified power supply) mounted on a number (No)
backing board which is:
(i) 900 mm wide x 150 mm high number (No)
(ii) 1 200 mm wide x 200 mm high number (No)
(b) Flashing LED illuminated arrow board number (No)

(c) Illuminated road sign – R & TR series (diameter indicated) number (No)
(d) Illuminated road sign – TW series (length of sides indicated) number (No)
(e) Mobile variable message sign number (No)
(f) Mobile variable message sign with a speed measuring and display capability month
C1.5.7.6 Maintenance of illuminated traffic signs:
(a) Sign mounted flashing amber lights (a pair of two lights mounted on a separate backing board) month
(b) Flashing LED illuminated arrow board month
(c) Illuminated road sign – R & TR series (diameter indicated) month
(d) Illuminated road sign – TW series (length of sides indicated) month
(e) Mobile variable message sign month
(f) Mobile variable message sign with a speed measuring and display capability month
C1.5.7.7 Traffic calming devices:
(a) 25 mm high x 100 mm wide asphalt rumble strips metre (m)
(b) 50 mm high x 500 m wide asphalt rumble strips metre (m)
(c) 150 mm high x 3 m wide asphalt speed control humps metre (m)
C1.5.7.8 Traffic control stations month
C1.5.7.9 Cleaning of traffic control facilities month
The unit of measurement for items C1.5.7.1(a), C1.5.7.1(b) and C1.5.7.2 shall be the number of delineators or traffic cones used on site. The
contract rates shall include full compensation for the provision, placing and relocation of delineators and traffic cones as often as required.
Payment for these items shall only be made once when they are first provided on site regardless of how many times they are repositioned and
reused during the construction of the Works.
The unit of measurement for items C1.5.7.3 and C1.5.7.4 shall be the number of flagmen and traffic controllers respectively employed for a
working shift in accordance with the requirements specified in Clause A1.5.7.11(e). The contract rate shall include full compensation for the
provision of trained flagmen and traffic controllers and for all wages, Employer contributions, accommodation, transport and other staff related
costs incurred by the Contractor, including their recruitment and training costs.
The contract rate shall also include full compensation for providing all flagmen and traffic controllers with conspicuous orange or bright yellow
clothing and safety boots, safety jackets utilizing retro-reflective and/or fluorescent panels in red, yellow and/or white as well as a red warning
flag or an amber LED strobe wand during hours of darkness as specified in Clauses A1.5.6.2e) and f).
The unit of measurement for items C1.5.7.5(a) to C1.5.7.5(f) shall be the number of illuminated traffic signs that are supplied and delivered to site
as specified in the Contract Documentation and/or as specified by the Engineer. The contract rates shall include full compensation for the
provision of the illuminated traffic signs, including poles and brackets, portable mounting frames and ballast and portable trailers where
applicable, and for removing them from site when they are no longer required.
The unit of measurement for items C1.5.7.6(a) to C1.5.7.6(f) shall be the month or part thereof during the approved Contract Period that these
traffic safety devices are erected / positioned on site as specified. The contract rates shall include full compensation for maintaining the warning
signs, providing a suitable electricity power supply and relocating the warning signs as often as required during the construction period and for
removing them from site when they are no longer required.
The unit of measurement for items C1.5.7.7(a), C1.5.7.7(b) and C1.5.7.6(c) shall be the metre of rumble strip or speed control hump installed on
the road. The contract rates shall include full compensation for the provision and construction of the traffic calming devices.
The unit of measurement for item C1.5.7.8 shall be the month or part thereof during the approved Contract Period that each traffic control station
is in operation on the site of the Works. The contract rate shall include full compensation for the provision and construction/erection of the traffic
control shelter complete as specified in clause A1.5.6.1f) including the provision of the specified traffic signals, communication devices, flood
lighting and the cost of supplying electricity. The contract rates shall also include full compensation for moving the traffic control points to new
locations as often as required and for removing them from site when they are no longer required.
The unit of measurement for item C1.5.7.9. shall be the month or part thereof during the approved Contract Period that the traffic signs and
delineators on the Site of the Works are kept clean. The contract rate shall include full compensation for the cleaning of all the delineators and
signs on site at least once a week and more often if required as specified in Clause A1.5.7.11d).
C1.5.8 Traffic safety officer Man-month
The unit of measurement for item C1.5.8 shall be the months or part thereof during the approved Contract Period that each traffic safety officer is
deployed on the site of the Works. The contract rate shall include full compensation for the provision of a trained and experienced traffic safety
officer and for all wages, Employer contributions, accommodation, transport and other staff related costs incurred by the Contractor, including
their recruitment and training costs.
The contract rate shall also include full compensation for the provision of a safety jacket utilizing retro-reflective and/or fluorescent panels in red,
yellow and/or white, a cell-phone and anything else the traffic safety officer requires to fulfil his duties and obligations as specified in Clause
A1.5.7.12.
The contract rate shall also include full compensation for the provision, operation and maintenance of a vehicle provided for the sole use of the
traffic safety officer as specified in Clause A1.5.6.4, including the provision of an amber flashing roof light or light bar and a “TRAFFIC
CONTROL” warning sign.
C1.5.9 Traffic safety vehicle month
The unit of measurement for item C1.5.9 shall be the month or part thereof during the approved Contract Period that the traffic safety vehicle is
deployed on the site of the Works.
The contract rate shall include full compensation for the provision, operation and maintenance of a traffic safety vehicle, including the driver and
any assistants required, as specified in Clause A1.5.6.3, including the provision of an amber flashing roof light or light bar, a “TRAFFIC
CONTROL” warning sign, a high visibility reflective rear chevron panel and an approved proprietary rear mounted impact attenuator device.
C1.5.10 Tow trucks
C1.5.10.1 Provision of a tow truck on call for light vehicles weighing less than two tonnes month
C1.5.10.2 Provision of a tow truck on call for heavy vehicles weighing two tonnes or more month
The unit of measurement for items C1.5.10.1 and C1.5.10.2 shall be the month or part thereof during the approved Contract Period that the tow
trucks are ordered by the Engineer to be on call for use on the site of the Works whenever they are required.
The contract rate shall include full compensation for the provision when required, the operation and the maintenance of the tow trucks.
Payment for towing vehicles off the road and/or on to a storage or repair facility will not be made as this cost is to be recouped from the owner of
the towed vehicle by the Contractor or the tow truck operator.
C1.5.11 Provision of safety equipment for visitors
C1.5.11.1 Provision of reflective safety vests for visitors number (No.)
C1.5.11.2 Provision of hard hats for visitors number (No.)
The unit of measurement for items C1.5.11.1 and C1.5.11.2 shall be the number of each item provided as specified, and approved by the
Engineer. The contract rates for the various safety items shall include full compensation for provision thereof and maintenance in good working
order.
C1.5.12 Additional traffic accommodation facilities ordered by the Engineer:
C1.5.12.1 Provision of additional traffic accommodation facilities prov sum
The provisional sum allowed under item C1.5.12.1 shall cover for the provision, erection and later removal of all additional traffic accommodation
items that may be ordered by the Engineer. The provisional sum shall be paid in accordance with the provisions of the Contract Documentation.
The percentage under item C1.5.12.2 is a percentage of the amount spent under item C1.5.12.1 which shall include full compensation for all
handling costs, profit and all other charges for the provision, erection and later removal of the additional traffic accommodation facilities.

D1.5 ACCOMMODATION OF TRAFFIC
CONTENTS
D1.5.1 SCOPE
D1.5.2 GENERAL
D1.5.1 SCOPE
The product quality and safety compliance certificates mentioned in Clauses A1.5.5 and A1.5.6 shall be provided if requested by the Employer
or the Engineer.

1.6 CLEARING AND GRUBBING
CONTENTS
A1.6.1 SCOPE
A1.6.2 DEFINITIONS
A1.6.3 GENERAL
A1.6.5 MATERIALS
A1.6.8 WORKMANSHIP

A1.6 CLEARING AND GRUBBING

A1.6.1 SCOPE
This Section covers the clearing of the site and the grubbing necessary for construction of the Works. This includes the following:
• Clearing and grubbing in watercourses and for hydraulic structures.

• Removal of rubbish, unsuitable or waste material, weeds and other vegetation in urban road/street reserve areas.
• Clearing and grubbing of service trench and designated excavation areas.
• Clearing and grubbing of borrow pits and quarries.
• Clearing and grubbing of the road prism.
• Clearing outside the road prism to improve sight distances.
• Clearing and grubbing of fence lines and other ancillary work areas.
• Preparation of topsoil stockpile areas.
• Stockpiling of topsoil and windrowing of topsoil.
The clearing and grubbing of areas required for site offices, laboratories and the Engineer’s site accommodation shall be included in the work
required to erect these facilities.
A1.6.2 DEFINITIONS
Clearing - is the removal, loading and disposal of all trees (including designated and protected trees if approved for removal), grass, brush,
shrubs, other vegetation, rubbish/litter, rocks and boulders of up to 0,15 m 3 in size which are exposed or lying on the surface and all other
unsuitable or waste material on or above ground level.
Clearing shall also include the removal of existing buildings, walls and other structures which encroach on or obstruct the Works and which can
be broken down and removed with a medium sized bulldozer. (Breaking down of reinforced concrete shall be specified separately in the
Contract Documentation if required.)
Removal of temporary works installed by the Contractor shall not be measured or paid for as clearing.
The removal, loading, transport, offloading and stacking (or disposal if specified in the Contract Documentation or by the Engineer) of existing
fences, road signs, guardrails, kerbing, channelling etc. shall be carried out as specified in the relevant sections of this Standard Specification.
Designated trees - are indigenous trees or heritage trees that may not be removed without the approval of the relevant local authority.
Designated spoil areas - are spoil or dump sites identified by the Employer in the Contract Documentation or identified by the Engineer on site
and those identified by the Contractor in the Contractor’s materials management and utilisation plan, as prepared in accordance with the
environmental regulations and the environmental management plan.
There are two types of designated spoil areas:
• Unsuitable material spoil areas identified on or near the site of the Works and which have been agreed to by the Engineer. In urban or
peri-urban areas the use of the spoil areas shall be approved by the local municipal authority in writing before any general unsuitable
material is deposited there.
• Hazardous waste spoil areas which shall be commercial or municipal waste sites that are registered to receive and dispose of
hazardous waste material.

Grubbing - is the removal and loading of all stumps and roots in areas where clearing has been carried out and the Engineer has confirmed in
writing that grubbing is also required. Grubbing also includes the removal and loading of all non-reinforced building foundations and floor slabs,
buried rubbish and other unsuitable or waste material.
Hazardous waste material - material that is cleared and grubbed shall be classified as hazardous waste material if it falls into the hazardous
waste categories identified in SANS 10228.
Protected trees - are trees as listed in the Schedule of Protected Trees given in the Government Gazette dated 8th September 2017 (or any
later amendments) issued in terms of Clause 15.3 in Chapter 3, Part 3 of the National Forests Act No. 84 of 1988. In terms of this Act protected
trees may not be pruned or removed without the permission of the Minister of Agriculture, Fisheries and Forestry.
Stockpile - is a pile of material pushed into a large heaped pile or off-loaded onto a heaped pile so that the material can be temporarily stored
for later re-use in the Works. Where specified the material to be placed in a stockpile shall be placed in evenly spread layers of a specified layer
thickness, up to the specified maximum height and to the specified shape.
Stockpile site - is a designated site that shall be prepared as specified in Chapter 4, Clause A4.1.7.3a).
Topsoil - is fertile, loamy soil obtained from areas with good soil coverage of natural vegetation, preferably grasses. It shall be free of
deleterious matter, such as stiff/heavy clays, large stones, large roots, refuse, rubble and construction material or waste, which will adversely
affect its suitability for the planting of grass.
Windrow - is a pile of material which has been excavated and pushed a relatively short distance to a prepared area alongside the borrow pit,
quarry, cutting or roadbed area so that the material can be temporarily stored for re-use, usually close to where it is windrowed.
A1.6.3 GENERAL

A1.6.5 MATERIALS

The provisions of Clause A1.2.6 of Section A1.2 shall apply to this Section A1.6.

A1.6.7.1 Areas to be cleared and grubbed
The portions of the road or street reserve falling within the limits of the road prism or site limits as well as borrow areas shall be cleared and
grubbed as specified in the Contract Documentation or as specified by the Engineer. Areas designated to be cleared and grubbed may also
include existing water courses, inlets and outlets of hydraulic structures, sidewalks, service trenches, designated excavations as defined in
Clause A4.2.2 of Chapter 4, fence lines and other ancillary road works which may fall outside the limits of the road prism. The Contractor shall
note that the presence of subsurface and / or surface water may prohibit the use of conventional machines for this work and the contract rates
should make allowance for alternative working methods and equipment where required.
Grubbing of part or all of the previously cleared areas may not always be necessary. Before commencing the grubbing operation, the Contractor
shall ask for a written instruction from the Engineer to confirm the position and extent of the cleared area/s that also need to be grubbed. Only
these area/s so confirmed in writing shall be grubbed and measured for payment.
Clearing, and grubbing where necessary, of new fence lines shall be done over a 2,0 m wide strip, 1,0 m either side of the staked fence line, as
described in Clause A11.5.7.3 of Chapter 11.
Clearing, and grubbing for new service trenches shall be carried out as specified in Clause A2.1.7.1e) of Chapter 2.
Where existing roads are to be widened the area to be cleared and grubbed shall also include the slope of the existing embankment where the
widening will take place.
Existing road lanes, whether surfaced or not, as well as existing sidewalks shall not be regarded as areas to be cleared and grubbed.
The Contractor shall identify all designated and protected trees, as defined in Clause A1.6.2, in consultation with the relevant authority. The
Contractor shall submit the details to the Engineer so that the Engineer can confirm in writing all the trees which must be left standing and
uninjured. Where the relevant permission has not been obtained to remove any designated and/or protected trees these trees shall be marked
for protection with plastic danger tape or other suitable means.
As stated in the Government Gazette dated 8th September 2017 (or in any later amendments that may be published) issued in terms of Clause
15.3 in Chapter 3, Part 3 of the National Forests Act No. 84 of 1988, the Contractor will be liable for a fine or a period of imprisonment of up to
three years for every protected tree which is unnecessarily removed or damaged.
All trees that are to be removed and that are equal to or greater than 1,0 m in girth shall be marked and counted. The tree count shall be agreed
with the Engineer for additional payment over the tendered clearing rate before the trees are cut down. All trees with a girth of less than 1,0 m
shall not be counted and shall be removed as part of the main clearing operation. The tree girth shall be measured at a height of 1,5 m above
the highest point where the tree trunk emerges from the ground. Where the tree is divided into two or more trunks, or has several trunks

growing from one stump or root base, the total girth for payment purposes shall be the sum of the individual girths of each trunk measured at a
height of 1,5 m above the highest point where each of the tree trunks emerge from the ground.
The Contractor shall be responsible for keeping the cleared and grubbed areas free of weeds and alien vegetation until the Works have been
completed and have been taken over by the Employer.
A1.6.7.2 Clearing
Clearing, as defined in Clause A1.6.2, shall be done with equipment which suits the type of material and terrain to be cleared and in a manner
which will result in minimal loss of topsoil. The cleared material shall be separated into re-usable material, unsuitable material and hazardous
waste and it shall be loaded and removed from the site immediately and transported to a designated stacking area, a designated spoil area or
an approved hazardous waste site as appropriate.
All undesignated trees, together with those protected trees or designated (indigenous or heritage) trees where the required permission to
remove them has been obtained, shall be cut down unless instructions have been given to retain any particular trees in the Contract
Documentation or by the Engineer.
The Contractor shall take the necessary precautions to prevent damage to structures and other private or public property. If necessary, the trees
shall be cut in sections from the top downwards.
The branches of any trees outside the roadbed area that are designated to be left standing shall be trimmed to provide a 7,0 m clearance above
the finished road level. The trimming of branches shall be done neatly by saw cutting as near as possible to the base of the branches.
Where clearing and grubbing would involve the cutting down of indigenous forest or commercial plantations the Contractor shall inform the
relevant authority or owner at least two months in advance before commencing with clearing and grubbing of such areas to allow them time to
salvage any usable timber before the trees are removed.
Where specified by the Engineer or in the Contract Documentation, clearing of hydraulic structures, where such work requires working to
prescribed levels or working without damaging existing structures, shall be carried out as specified in Chapter 3.
The removal, breaking up and disposal of existing kerbing, channelling, down-chutes etc. shall be carried out as specified in Chapter 3.
All re-usable fencing wire shall be neatly wound into reels and all such wire, together with all fence posts and other usable material shall be
removed as specified in Clause A11.5.7.9 of Chapter 11 and neatly stacked at sites indicated by the Engineer.
All re-usable road furniture such as road signs, guardrails, down-chutes etc. shall also be removed as specified in Clauses A11.4.7.3 and
A11.6.7.7 of Chapter 11 and neatly stacked at sites indicated by the Engineer.
All existing buildings and structures which encroach on or obstruct the Works shall be removed. All buildings and structures that must be
removed will be identified in the Contract Documentation and shall be confirmed with the Engineer in writing before the Contractor demolishes
and/or removes any structures or buildings.
A1.6.7.3 Conservation of vegetation

Prior to any clearing, any shrubs and trees encountered in the road reserve and borrow areas that have been designated for preservation in the
Contract Documentation, or in the environmental approval process, shall be carefully removed, correctly stored and maintained in a temporary
nursery until they are replanted within the road reserve as specified in Clause A11.8.7.5 of Chapter 11 or as specified by the Engineer.
A1.6.7.4 Grubbing
All stumps and roots, including matted roots, in the roadbed area shall be removed to a depth of at least 1,0 m below the cleared roadbed
surface.
Outside the roadbed area only stumps and roots, including matted roots, exceeding 75 mm in diameter shall be removed to a depth of at least
75 mm below the original ground level. The grubbed material shall be loaded and removed from the site immediately and disposed of at a
designated spoil area.
The foundations of any buildings or structures, buried rubbish, old rubbish tips, rubble or other unsuitable material shall be removed unless
otherwise instructed by the Engineer. The building material and unsuitable or waste material shall be loaded and removed from the site
immediately and disposed of at a designated spoil area.
Except in borrow areas, all cavities resulting from the grubbing shall be backfilled with approved material and compacted to a density of at least
the density of the surrounding ground.
A1.6.7.5 Clearing and grubbing in water courses and hydraulic structures

Clearing out existing culverts and bridges shall be carried out by hand to avoid damaging the structure apron slabs or headwalls. All sand and
silt cleaned out from the hydraulic structures may be disposed of by spreading it out inside the road reserve in suitable areas where the spoil
material does not block up the outlet drain. The spoil material shall not be deposited upstream of the structure where it can be washed back into
the structure by storm water run-off.
All unsuitable material cleaned out of the hydraulic structures shall be loaded and removed from the site immediately and taken to a designated
spoil area. It shall not be left buried in the spoil material near the structure.
While working in or near a water course the Contractor shall take care not to unduly disturb the vegetation which is preventing erosion or to
contaminate the water course with any hazardous material such as oil or fuel from his vehicles and equipment. The Contractor shall also ensure
that none of his clearing and grubbing operations block any waterways, thereby causing the water to dam up.
After the clearing of the hydraulic structures has been completed the Contractor shall be responsible for maintaining them in a clean condition
for the duration of the contract as part of the routine maintenance operations.
A1.6.7.6 Conservation of topsoil

Where suitable topsoil occurs within the limits of the areas to be cleared and grubbed, the Contractor shall do the clearing and grubbing without
removing any more topsoil than is absolutely necessary.
At the commencement of the Works the Contractor shall confirm with the Engineer the quantity of topsoil that is required and from where the
topsoil shall be selected and removed by the Contractor. All suitable topsoil available from the roadbed areas and cuttings on site, as well as

from areas that are to be cleared for borrow pits and quarries, shall then be removed as specified in the Contract Documentation and/or by the
Engineer. If the Contractor fails to conserve all the available topsoil he shall obtain suitable substitute topsoil from other sources at his own cost.
The depth of topsoil excavation or removal shall be controlled to suit the thickness of suitable material available and shall not exceed a
maximum depth of 400 mm.
The topsoil shall either be bladed to windrow or excavated, loaded, hauled, off-loaded and stockpiled in loose heaps as off-loaded from the haul
vehicles or in neatly shaped stockpiles that do not exceed 2,0 m in height. Care must be taken to ensure that no topsoil is compacted by
vehicles driving over the windrows or stockpiles of topsoil.
Any deleterious material, such as stiff/heavy clays, large stones, large roots, refuse, rubble and construction material or waste, which will
adversely affect its suitability for the planting of grass shall be removed before the topsoil is excavated.
Before removing any topsoil to stockpile, designated topsoil stockpile sites shall be prepared as specified in Clause A4.1.7.3a) of Chapter 4. The
topsoil stockpile sites shall either be situated immediately alongside the borrow pits and quarries or situated as close as possible to the cuttings
and roadbed preparation areas, unless otherwise specified by the Engineer.
Topsoil infested with weeds shall be stockpiled or windrowed separately so that the weeds can be removed. All the topsoil stockpiles and
windrows, as well as the area immediately surrounding the stockpiles and windrows, shall be kept free of weeds and shall not be contaminated
with any spoil material or construction material, especially gravel, crushed stone and bitumen.
When no longer required the topsoil stockpile sites shall then be reinstated as specified in Clause A4.1.7.3c) of Chapter 4.
Where the existing in-situ topsoil is intended to be re-used nearby, such as for reinstating borrow pits and quarries for example, the Engineer
may specify that the topsoil should be pushed directly into windrows alongside the area from which it is excavated.
A1.6.7.7 Disposal of material

Material obtained from clearing and grubbing shall be separated into organic material, reusable material, unsuitable material and hazardous
waste material and immediately disposed of as follows:
• Organic matter shall be disposed of in designated spoil areas or in borrow pit excavations prior to their rehabilitation, as instructed by
the Engineer. The organic matter shall be spread evenly over the designated dumping area and covered up with soil to a depth of at
least 150 mm, unless otherwise instructed by the Engineer. The burning of organic matter will not normally be permitted and may be
done only with the prior written approval of the Engineer and the local fire control authority and strictly in accordance with the
environmental management plan. All statutory provisions regarding air pollution shall be carefully observed. If specified in the Contract
Documentation, selected organic matter obtained from clearing and grubbing shall be mulched.
• Reusable material shall be transported to a designated storage site and neatly stacked.
• Non-hazardous unsuitable material such as building rubble etc. shall be disposed of in designated spoil areas or placed in temporary
stockpiles for use elsewhere in the Works, as instructed by the Engineer.
• Hazardous waste shall be disposed of in commercial or municipal waste sites that are registered to receive and dispose of hazardous
waste material.
A1.6.7.8 Re-clearing vegetation

The Contractor shall carry out the clearing and grubbing at the last practicable stage before each part of the construction work commences. All
re-clearing that is required because the initial clearing was carried out too soon shall not be measured for payment.
When portions of the road reserve, borrow or other areas have been cleared in accordance with the specifications but vegetation grows again
during the construction period, the Engineer may, if he considers it necessary, order that the area be re-cleared.
A1.6.8 WORKMANSHIP
Reserved for future use.

B1.6 CLEARING AND GRUBBING
CONTENTS
B1.6.1 SCOPE
B1.6.2 DEFINITIONS
B1.6.3 GENERAL
B1.6.5 MATERIALS

B1.6.8 WORKMANSHIP
B1.6.1 SCOPE
Where specified in the Contract Documentation labour enhancement methods shall be used to carry out the applicable clearing and grubbing
operations or parts of these operations.
B1.6.2 DEFINITIONS
B1.6.3 GENERAL

B1.6.5 MATERIALS

Where reference is made in PART A to appropriate equipment, the use of light equipment shall be evaluated during trial sections.

Operations such as the clearing of hydraulic structures, cutting down of trees and removal of fencing, road signs, guardrails etc. are all classed
as labour enhancement operations.
B1.6.8 WORKMANSHIP

C1.6 CLEARING AND GRUBBING
(i) Preamble
otherwise stated.
deemed appropriate:
1. Loading and offloading of cleared material and grubbed material.
2. Keeping the cleared and grubbed areas free of weeds and alien vegetation until the Works have been completed and have been taken
over by the Employer, as specified in Clause A1.6.7.1.
3. Removing deleterious or unsuitable material that was not properly removed during the clearing and grubbing operation from areas where
topsoil is to be stockpiled or windrowed, as specified in Clause A1.6.7.6.
4. Keeping topsoil stockpiles and windrows free of weeds, as specified in Clause A1.6.7.6.
5. Re-clearing areas that were cleared and grubbed too far in advance of the Works, as specified in clause A1.6.7.8.
For activities shown in Table C1.6-1 payment items specified in other chapters or sections of the specifications, where they relate to work under
this section, will be listed in the Pricing Schedule.
Clearing and grubbing for site offices, laboratories and site

A1.6.1 Included in item C1.4.1 of Chapter 1
accommodation
Hauling of cleared and grubbed material to designated spoil
A1.6.7.2, A1.6.7.4, A1.6.7.5 C1.7.2 of Chapter 1
areas
Clearing and shaping accumulated sediment in existing
A1.6.7.2 C3.1.2 of Chapter 3
unlined open drains
Excavating and clearing accumulated sediment in existing
A1.6.7.2 C3.1.3 of Chapter 3
lined drains and drainage systems
Removal, breaking up, loading, transporting and disposal of
A1.6.7.2 C3.3.16 of Chapter 3
concrete kerbing, channelling, down-chutes etc.
Removal, loading, transporting, offloading and stacking of
A1.6.7.2 C11.4.7 of Chapter 11
guardrails
Moving or removal and loading, transporting, offloading and
A1.6.7.2 C11.5.3 & C11.5.4 of Chapter 11
stacking of fencing and gates
Removal, loading, transporting, offloading and storage of C11.6.6, C11.6.7
A1.6.7.2
road signs & C11.6.10 of Chapter 11
Replanting of shrubs and trees from a site nursery A1.6.7.3 C11.8.9.2 of Chapter 11
Preparation of topsoil stockpile sites A1.6.7.6 C4.1.10 & C4.1.11 of Chapter 11

C4.1.13, C4.1.14 and C4.1.15.1(c) /
Reinstatement of topsoil stockpile sites A1.6.7.6 C4.1.15.2(c) of Chapter 4 as
applicable
Hauling topsoil to stockpile A1.6.7.6 C1.7.2.1(a) of Chapter 1

(iv) Items specifically for this Section of the Specifications

C1.6.1 Clearing
C1.6.1.1 Clearing with machines and some hand labour where necessary hectare (ha)
C1.6.1.2 Clearing with hand labour only when labour enhanced work is specified hectare (ha)
C1.6.1.3 Clearing for new fence lines (over a width of 2,0 m) kilometre (km)
C1.6.1.4 Clearing for service trenches (over the agreed width required) square metre (m2)
The unit of measurement for items C1.6.1.1 and C1.6.1.2 is the hectare. The quantity shall be taken as the area (to the nearest 0,01 ha)
designated by the Engineer and cleared in accordance with this Standard Specification.
The unit of measurement for item C1.6.1.3 is the kilometre of 2,0 m wide cleared fence line strip.
The unit of measurement for item C1.6.1.4 is the square metre of cleared area along the service trench. The area to be measured shall be
calculated by multiplying the length cleared by the agreed width required to excavate the trench, temporarily stockpile the excavated material
alongside and place the service materials alongside the trench prior to installation.
The contract rate shall include full compensation for all work necessary for the clearing of the surface, the removal of rocks and boulders up to
0,15 m3 each in size, the removal of grass, bushes, shrubs, any other vegetation, all trees with a girth of less than 1,0 m, cutting of branches,
demolishing of structures or parts of structures (except those structures specifically listed in the Contract Documentation and measured
separately under item C1.6.4,) and the loading of the cleared material.
Hauling of the cleared material to a designated spoil area will be measured from the point of loading to the centroid of the designated spoil area
following the shortest practical route. Payment for haulage will be made under item C1.7.2.
No additional payment will be made for the removal of a certain amount of sand, soil or gravel material which may be inherent in, or
unavoidable, during the process of clearing, regardless of the quantity removed.
Where topsoil can be removed without the necessity of first doing clearing, no payment will be made for clearing.

C1.6.2 Grubbing
C1.6.2.1 Grubbing with machines and some hand labour where necessary hectare (ha)
C1.6.2.2 Grubbing with hand labour when labour enhancement work is specified or it is not practical to hectare (ha)
use a machine
C1.6.2.3 Grubbing by hand for new fence lines (over a width of 2,0 m) kilometre (km)
C1.6.2.4 Grubbing by hand for service trenches (over the agreed width required) square metre (m2)
The unit of measurement for items C1.6.2.1 and C1.6.2.2 is the hectare. The quantity shall be taken as the area measured in hectares (to the
nearest 0,01 ha) as designated by the Engineer in writing and grubbed in accordance with these specifications.
The unit of measurement for item C1.6.1.3 is the kilometre of 2,0 m wide cleared fence line strip.
The unit of measurement for item C1.6.1.4 is the square metre of cleared area along the service trench. The area to be measured shall be
calculated by multiplying the length cleared by the agreed width required to excavate the trench, temporarily stockpile the excavated material
alongside and place the service materials alongside the trench prior to installation.
The contract rate shall include full compensation for all work necessary for the grubbing the area, removing all tree roots larger than 75 mm in
diameter and all tree stumps, backfilling of cavities, demolishing and disposal of foundations of buildings and structures, the removal of rubbish,
rubble or other unsuitable or waste material and the loading and offloading of the grubbed material. Hauling of the grubbed material to a
designated spoil area will be measured from the centroid of the loading area to the centroid of the designated spoil area following the shortest
practical route. Payment for haulage will be made under item C1.7.2.
No additional payment will be made for the moving of a certain amount of soil or gravel material which may be inherent in, or unavoidable,
during the process of grubbing, regardless of the quantity removed.
Only the areas confirmed in writing by the Engineer to be grubbed shall be measured for payment.

C1.6.3 Removal and grubbing of large trees and tree stumps:
C1.6.3.1 Girth equal to or exceeding 1,0 m up to and including 2,0 m number (No)
C1.6.3.2 Girth exceeding 2,0 m up to and including 3,0 m number (No)
C1.6.3.3 Girth exceeding 3,0 m number (No)
C1.6.3.4 Removal of trees in forests and plantations hectare (ha)
The unit of measurement for items C1.6.3.1 to C1.6.3.3 shall be the number of trees of each size removed. The girth of trees and stumps shall
be measured as specified in Clause A1.6.7.1. Trees and stumps with a girth exceeding 1,0 m shall be measured individually and classified in
size increments exceeding 1,0 m up to 2,0 m, exceeding 2,0 m up to 3,0 m and exceeding 3,0 m, as indicated in the items above. (Trees with a
girth of less than and up to 1,0 m shall not be paid for individually and the cost of removing all small trees and bushes with a girth of less than
and up to 1.0 m shall be included in the contract rates for item C1.6.1 and item C1.6.2.)
The contract rates shall include full compensation for all work necessary for the removal and grubbing of trees and stumps of all sizes, including
removal of the roots, the backfilling and compaction of the cavities left after the stump and roots have been removed with approved material,

and the loading and offloading of the cut timber and grubbed root material. Hauling of the grubbed material to a designated spoil area will be
measured from the centroid of loading area to the centroid of the designated spoil area following the shortest practical route. Payment for
haulage will be made under item C1.7.2.
Where construction is carried out through forests or plantations, or where the number of trees with a girth exceeding 1,0 m renders individual
measurement impracticable, the removal and grubbing of trees in such areas shall be measured under item C1.6.3.4. The quantity shall be
taken as the area measured in hectares (to the nearest 0,01 ha) as designated by the Engineer in writing. If this method of measurement is
used, the areas where it applies will be shown on the drawings, stated in the Contract Documentation and/or indicated to contractors during the
site inspection. The contract rate per hectare shall include full compensation for all work as described for the removal of individual trees above.

C1.6.4 Removal of buildings and structures
C1.6.4.1 (Identify type and location of each building or structure with a separate sub-item) lump sum
The unit of measurement for each building or structure that is removed shall be the lump sum. The lump sum shall include full compensation
for all work necessary for demolishing and removing the buildings or structures, including removal of the foundations and the loading and
offloading of all the material. Hauling of the removed building or structural material to a designated spoil area will be measured from the point
of loading to the centroid of the designated spoil area following the shortest practical route. Payment for haulage will be made under item
C1.7.2.

C1.6.5 Spreading organic matter and covering with soil cubic metre (m3)
The unit of measurement for item C1.6.5 shall be the cubic metre of organic matter, measured as 50% of the measured load volume of the
haul vehicle being used, spread out at the designated spoil site or in the borrow pit, as instructed by the Engineer, and covered with enough
soft material to fill the voids and provide a covering layer at least 150 mm thick over all the spread material.

C1.6.6 Mulching selected organic matter cubic metre (m3)
The unit of measurement for item C1.6.5 shall be the cubic metre of organic matter that is selected from the cleared and grubbed material, cut
and shredded to make a mulch and stockpiled or spread out at the designated area, as instructed by the Engineer.
The volume shall be measured loose in stockpile or calculated from an agreed estimate of the area covered by the mulch multiplied by the
agreed average spread depth.

C1.6.7 Re-clearing of previously cleared areas hectare (ha)
The unit of measurement for item C1.6.7 shall be the hectare. The quantity shall be taken as the area in hectares (to the nearest 0,01 ha)
agreed to by the Engineer for re-clearing in accordance with these specifications.
The contract rate shall include full compensation for all work necessary for the clearing of the surface, grubbing if necessary, backfilling of
holes and for loading the material, all as described in this section. Hauling of the re-cleared material to a designated spoil area will be
measured from the point of loading to the centroid of the designated spoil area following the shortest practical route. Payment for haulage will
be made under item C1.7.2.
(Re-clearing required because the Contractor cleared and grubbed an area too soon, as well as keeping cleared areas free from weeds and
alien vegetation, is the Contractor’s responsibility and will not be measured and paid for under this item.)

C1.6.8 Conservation of vegetation:
C1.6.8.1 Establishment of a temporary nursery number (No)
C1.6.8.2 Removal, storage and maintenance of shrubs number (No)
C1.6.8.3 Removal, storage and maintenance of trees, girth up to and including 1,0 m number (No)
C1.6.8.4 Removal, storage and maintenance of trees, girth exceeding 1,0 m up to and including 2,0 m number (No)
C1.6.8.5 Removal, storage and maintenance of trees, girth exceeding 2,0 m up to and including 3,0 m number (No)
C1.6.8.6 Removal, storage and maintenance of trees, girth exceeding 3,0 m number (No)
The unit of measurement for item C1.6.8.1 shall be the number of temporary nurseries established on site as agreed with the Engineer. The
contract rate shall include full compensation for clearing and levelling the nursery site, installing fencing, shade netting and wind breaks, for
providing plant containers where necessary and for installing a water supply system.
The unit of measurement for items C1.6.8.2 to C1.6.8.6 shall be the number of shrubs or trees of each size removed from site and
replanted/stored and maintained in a temporary nursery. The contract rate shall include full compensation for all work necessary for carefully
removing the shrubs and trees with their root systems intact and for correctly replanting, storing, watering and maintaining them in a
temporary nursery until they are removed for replanting.

C1.6.9 Conservation of topsoil:
C1.6.9.1 Stockpiling topsoil cubic metre (m3)
C1.6.9.2 Windrowing topsoil cubic metre (m3)
The unit of measurement for item C1.6.9.1 shall be the cubic metre of topsoil stockpiled. The contract rate shall include full compensation for
excavating, loading, off-loading and stockpiling the topsoil at the designated stockpile site. Hauling of the topsoil to a designated stockpile site
will be measured from the centroid of the loading area to the centroid of the designated stockpile site following the shortest practical route.
Payment for haulage will be made under item C1.7.2.
The unit of measurement for item C1.6.9.2 shall be the cubic metre of topsoil excavated and placed into windrows. The contract rate shall
include full compensation for excavating and moving the material into windrows in the designated storage area.

C1.6.10 Disposal of hazardous waste material:
C1.6.10.1 Disposal of hazardous waste material at an approved hazardous waste material facility. provisional sum
The provisional sum allowed under item C1.6.10.1 shall cover the cost of disposing hazardous waste material at an approved hazardous
waste facility, extra over the cost of clearing and/or grubbing the hazardous waste material which is paid for under items C1.6.1 and/or
C1.6.2. The provisional sum shall be paid in accordance with the provisions of the Contract Documentation.
The percentage under item C1.6.10.2 is a percentage of the amount spent under item C1.6.10.1 which shall include full compensation for
all handling costs, profit and all other charges for the disposal of the hazardous waste material.

D1.6 CLEARING AND GRUBBING
CONTENTS
D1.6.1 SCOPE
D1.6.2 GENERAL
No specific items in this Section.
Where applicable, details must be provided in the Contract Documentation.

1.7 LOADING AND HAULING
CONTENTS
A1.7.1 SCOPE
A1.7.2 DEFINITIONS
A1.7.3 GENERAL
A1.7.5 MATERIALS
A1.7.8 WORKMANSHIP

A1.7 LOADING AND HAULING

A1.7.1 SCOPE
This Section covers the loading and hauling of construction materials on the site of the Works.
A1.7.2 DEFINITIONS
Hauling - is the moving of loaded construction material from the point of excavation, or from a stockpile or windrow, to the point of use on the
site or to designated spoil areas. The hauling operation shall include the off-loading of the material at the point of use on site, at the temporary
stockpiles or at the designated spoil sites as applicable.
Haul roads - are temporary roads constructed by the Contractor, or existing public or privately owned roads, or any part or section of the road
under construction, used for the purposes of hauling construction materials or for carting material to spoil.
Loading - is the operation of picking up the material from an excavation, stockpile or windrow and placing it in a haul vehicle.
A1.7.3 GENERAL
A1.7.3.1 Measurement of haul distance
The haul distance shall usually be measured from the centre of volume (centroid) of the excavation in the cutting (or part of a cutting), trench or
borrow pit, or from the centre of the stockpile position where applicable, to the centroid of the fill (or part of a fill), to the mid-point along the road
centreline of the section of the road layer where the material is placed, to the centre of the temporary stockpile position in a borrow pit, quarry or
on site or to the centre of the designated spoil area where the material is off loaded as applicable. The haul distance will be measured to the
nearest 0,1 km.
For those operations where the material is usually disposed of, and/or reused, near the source of the material the relevant pay item may state
that the cost of hauling the material for the first 1,0 km shall be included in the contract rate for that pay item. For these operations the hauling of
the material shall only be measured if the actual haul distance exceeds 1,0 km and the haul distance to be measured for payment shall be
measured from a point starting 1,0 km from the centre of volume (centroid) of the excavation in the trench or borrow pit, or from the centre of the
stockpile position where applicable, up to the centroid of the fill (or part of a fill), up to the mid-point along the road centreline of the section of
the road layer where the material is placed or up to the centre of the designated spoil area where the material is off loaded as applicable. The
haul distance will be measured to the nearest 0,1 km.
The haul distance shall be measured along the shortest route as instructed by the Engineer as being safe and practical. The haul distance shall
include any distance that the haul vehicle must travel to make use of a safe turning point or the next off ramp before making the return trip.
Should the Contractor choose to haul material over some other longer route, computations for payment shall nevertheless be based on the haul
distance measured along the shortest route instructed by the Engineer.
A1.7.3.2 Haul and construction access roads

The construction, use and later closure / reinstatement of any haul roads and construction access roads that are required by the Contractor shall
be carried out in accordance with the requirements given in Clause A4.1.7.1 of Chapter 4.
The requirements for the use of any existing public roads by the Contractor to haul material are given in Clause A4.1.7.1a) of Chapter 4.
The requirements for the use of haul roads not on existing public roads are given in Clause A1.2.3.2.
A1.7.5 MATERIALS

The provisions of Clause A1.2.6 in Section A1.2 shall apply to this Section.

The loading, hauling, off-loading and spreading of all material shall be carried out in any suitable manner chosen by the Contractor provided no
excessive segregation or contamination of the material occurs during any of these operations. If any segregation or contamination that the
Engineer determines to be excessive does occur the Contractor shall change his methods of operation to eliminate the excessive segregation or
contamination.
In addition to the material origin and destination records, a daily record of the registration numbers, measured level load volumes and the
number of trips made by haul vehicles taking material to spoil shall also be kept by the Contractor for all volumes that are measured by loose
volume in the haul vehicle. All the daily records shall be submitted to the Engineer no later than 10h00 the following working day. Failure on the
part of the Contractor to do so will entitle the Engineer to make his own calculations regarding the volume of material moved as well as the haul
distance and the Engineer’s calculations will then be final and binding for measurement and payment purposes.
The Contractor shall ensure that the vehicles used to haul construction materials are not overloaded and the legal axle loads are not exceeded.
Where specified in the Contract Documentation, the Contractor must provide the Engineer with the certified carrying capacity of each vehicle
before any construction materials can be transported.
Unless otherwise specified in the Contract Documentation any truck that is overloaded shall not be allowed to discharge/off-load its load and the
overloaded truck shall return to the borrow pit/quarry/depot/batching plant for adjustment of the load. In addition, a penalty shall be applied for
the overload. The penalty amount per tonne of overload stated in the Contract Documentation multiplied by the distance that the load was
hauled will be deducted on the front page of the payment certificate. Such penalty shall not be deducted from the value of work done in
calculating contract price adjustment value.
A1.7.8 WORKMANSHIP
Reserved for future use.

B1.7 LOADING AND HAULING
CONTENTS
B1.7.1 SCOPE
B1.7.2 DEFINITIONS
B1.7.3 GENERAL
B1.7.5 MATERIALS
B1.7.8 WORKMANSHIP
B1.7.1 SCOPE
Where specified in the Contract Documentation, or where it is more practical to do so, the loading operations shall be carried out using hand
labour instead of construction equipment.
B1.7.2 DEFINITIONS
B1.7.3 GENERAL

B1.7.5 MATERIALS

Where reference is made in PART A to appropriate equipment, the use of light equipment shall be evaluated during trial sections. The
specifications in Part A shall be equally applicable.

The loading of small volumes of material obtained from the excavation for services, clearing of hydraulic structures, loading of spoil from minor
works operations and final clearing and grubbing operations are suitable components for labour enhancement.
B1.7.8 WORKMANSHIP

C1.7 LOADING AND HAULING
(i) Preamble
otherwise stated.
The following required activities will not be measured or paid for separately and the Contractor shall include the cost of these activities in other
pay items as already specified for the appropriate pay item or as deemed appropriate by the Contractor:
1. The loading and hauling of commercial materials from either Employer or Contractor identified suppliers/sources shall not be measured for
payment.
2. The loading of materials on site will not be measured and paid for separately except for loading already stockpiled material and for loading
material that has been placed in heaps or windrows where the relevant payment item in other Chapters specifically states that the loading
will be paid for separately.
3. The hauling of materials on site will not be measured and paid for separately where the relevant payment item specifically states that the
hauling operation is included in that payment item.
4. The hauling of materials on site over a localised distance of up to 1,0 km will not be measured and paid for separately where the relevant
payment item specifically states that the initial haul of the material over a distance of up to 1,0 km is included in the pay item.
There are no items mentioned in this section that are measured and paid for elsewhere in this Standard Specification.
The following payment items will be inserted in the Pricing Schedule under the relevant payment section where loading and/or hauling of
materials is applicable. The payment item shall commence with the relevant section number followed by / and then by the applicable loading
and hauling payment item numbers given here.
C1.7.1 Loading
C1.7.1.1 Loading from stockpile using machines and some hand labour where necessary cubic metre (m3)
C1.7.1.2 Loading from heaps or windrows using machines and/some hand labour where necessary cubic metre (m3)
C1.7.1.3 Loading by hand only from stockpile or heaps when labour enhancement work is specified or cubic metre (m3)
it is not possible to use machines
Loading is generally considered to be part of the operation that produced the material which is being loaded, such as excavation, grubbing,
cleaning, demolition etc., and it is therefore not usually measured separately for payment. Loading shall only be measured separately for
payment for loading stockpiled material and for loading material that has been placed in heaps or windrows where the relevant payment item
specifically states that the loading will be paid for separately.
The unit of measurement for items C1.7.1.1 to C1.7.1.3 shall be the cubic metre of material loaded into the hauling vehicles. These pay items
shall only apply for those activities where the relevant pay item does not specify that the loading is included in the contract rate for that pay item.
The quantity of all soil and gravel materials loaded for hauling for use on the site of the Works shall be the compacted volume of material
measured in its final position in the Works calculated using the dimensions given in the Contract Documentation or specified in writing by the
Engineer.
The quantity of all materials loaded for hauling to temporary stockpile for later use in the Works, to borrow pits for backfilling purposes or for
disposal at designated spoil areas shall be taken as 70% of the measured load volume of the haul vehicle being used to transport soil and gravel
material and 50% of the measured load volume of the haul vehicle being used to transport hard material and/or boulders.
The contract rate for item C1.7.1.1 shall include full compensation for loading material from a stockpile and loading it into the hauling vehicles.
The contract rate for item C1.7.1.2 shall include full compensation for loading excavated material from heaps or windrows at the point of
collection, including any windrowing and/or localised sorting / stockpiling that may be required, and loading it into the hauling vehicles.
The contract rate for item C1.7.1.3 shall include full compensation for loading excavated material at the point of collection on site or loading it
from stockpile by hand and loading it by hand into the hauling vehicles. This item is only applicable when the Contractor has been instructed to
load the material by hand in the Contract Documentation or by the Engineer to enhance the labour component of the Works or if it is not practical
to use machines due to the restricted nature of the work.

C1.7.2 Hauling
C1.7.2.1 Hauling material for use in the Works and off-loading it on the site of the Works:
(a) Soil, gravel, crushed stone and pavement layer material cubic metre - kilometre (m3 - km)
(b) Boulders and hard material cubic metre - kilometre (m3 - km)
C1.7.2.2 Hauling material to spoil and off-loading it at a designated spoil or stockpile area:
(a) Cleared and grubbed material (organic matter and all other unsuitable or waste cubic metre - kilometre (m3 - km)
material)
(b) Soil and gravel material cubic metre - kilometre (m3 - km)
(c) Boulders, hard material and concrete cubic metre - kilometre (m3 - km)
The unit of measurement for items C1.7.2.1 and C1.7.2.2 shall be the cubic metre – kilometre (m3 - km) which is calculated as the product of the
quantity of material loaded, as measured in items C1.7.1.1, C1.7.1.2 or C1.7.1.3, multiplied by the applicable haul distance which shall be
calculated as defined in Clause A1.7.3.1.
These pay items shall only apply for those activities where the relevant pay item does not specify that all the hauling is included in the contract
rate for that pay item.
The quantity of all soil and gravel materials hauled for use on the site of the Works shall be the compacted volume of material measured in its
final position in the Works calculated using the dimensions given in the Contract Documentation or specified in writing by the Engineer.
The quantity of all materials hauled to temporary stockpile for later use in the Works, to borrow pits for backfilling purposes or to designated spoil
areas shall be taken as 70 % of the measured load volume of the haul vehicle being used to transport soil and gravel material and 50 % of the
measured load volume of the haul vehicle being used to transport hard material and boulders.
The quantity of all organic matter hauled to borrow pits or to designated spoil areas shall be taken as 50 % of the measured load volume of the
haul vehicle being used.
The contract rate shall include full compensation for hauling the material and off-loading it at the required or designated position.

D1.7 LOADING AND HAULING
CONTENTS
D1.7.1 SCOPE
D1.7.2 GENERAL

South Africa
COTO
Officials


CHAPTER 2: SERVICES
October 2020

FOREWORD

Published by:

industry.
The new COTO Standard Specifications for Road and Bridge Works for South African Road Authorities was approved by COTO
on 18 August 2020 as a Draft Standard (DS) and will be replacing the COLTO Standard Specifications for Road and Bridge
Works for State Road Authorities (1998 Edition).
Document versions:
COTO subcommittee. The document is converted to a Final Standard (FS) and submitted by the Roads Coordinating Body
(RCB) to COTO for approval as a final standard. This Final Standard is implemented in industry for a period of five (5) years,
after which it may again be reviewed. Final Standards (FS) have full legal standing.
Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 2: SERVICES ......................................................................................................................................... 2-1
2.1 GENERAL REQUIREMENTS AND TRENCHING FOR SERVICES ........................................................... 2-1
PART A: SPECIFICATIONS .............................................................................................................................................................................. 2-1
PART B: LABOUR ENHANCEMENT ............................................................................................................................................................... 2-16
PART C: MEASUREMENT AND PAYMENT ................................................................................................................................................... 2-18
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES ...................................................................................................................... 2-28
2.2 DRY SERVICES ......................................................................................................................................... 2-29

PART A: SPECIFICATIONS ............................................................................................................................................................................ 2-29
2.3 WET SERVICES ......................................................................................................................................... 2-41

2.4 ENERGY AND OTHER SERVICES ........................................................................................................... 2-59

CHAPTER 2: SERVICES
2.1 GENERAL REQUIREMENTS AND TRENCHING FOR SERVICES
CONTENTS
A2.1.1 SCOPE
A2.1.2 DEFINITIONS
A2.1.3 GENERAL
A2.1.5 MATERIALS
A2.1.8 WORKMANSHIP

A2.1 GENERAL REQUIREMENTS AND TRENCHING FOR SERVICES

A2.1.1 SCOPE
Section A2.1 covers the general requirements applicable to civil construction work associated with the location, identification, protection, relocation
and the installation of services in existing or new road reserves or servitudes as well as the protection and reinstatement of existing road
infrastructure affected in the process of dealing with such services. This Section also covers the trenching requirements applicable to the
installation of services in road reserves. Section A2.1 covers services installed as individual services as well as when they are to be installed as
part of a larger construction contract. Chapter 2 does not cover stormwater and other drainage structures which are specified in Chapter 3.
A2.1.1.1 Installation of new services

The construction work associated with the installation of new (utility) services in road reserves including the installation of new dry services (ducts
for cables for communications and electric power etc.) are covered in Section A2.2, the installation of new wet services (water supply and waste
water (sewerage) pipelines etc.) are covered in Section A2.3 and the installation of street lighting, electric power and energy services (gas and
fuel pipelines) as well as the installation of other new services as may be specified in the Contract Documentation are covered in Section A2.4.
A2.1.1.2 Location, identification, protection and relocation of existing services

Section A2.1 also covers the work associated with the location and identification of all existing services on the site and the protection and/or
relocation of existing services. Existing services shall be located, identified and protected or relocated in accordance with the details shown on
the drawings, provided in the Contract Documentation or as directed by the Engineer.
A2.1.1.3 General note

In certain SANS documents referred to in this section the term “specified in the scope of work” is used. For the purposes of this specification the
term shall be deemed to mean “specified in the Contract Documentation”.
A2.1.1.4 Applicable supporting specifications

Section A2.1 of Chapter 2 shall be used in conjunction with, amongst others, the following standards or specifications:
SANS 241-1 Drinking water Part 1: Microbiological, physical, aesthetic and chemical determinands
SANS 2001-DP1 Earthworks for buried pipelines and prefabricated culverts
SANS 51008 Mixing water for concrete – Specification for sampling, testing and assessing the suitability of
water, including water recovered from processes in the concrete industry, as mixing water for
concrete
Where the documents referenced are undated the latest edition of the referenced document (including any amendments) shall apply. Where
references are dated only the edition cited shall apply.

A2.1.2 DEFINITIONS
The following definitions shall apply to these specifications:
Affected Parties - all persons or organisations that may be affected by the construction work and shall include all Service Owners.
Backfill - approved compacted materials used to replace excavated materials from the top of the fill blanket or bedding up to the surrounding
ground level or the bottom of the pavement layer works, whichever is the lowest.
Cables - power and auxiliary conductors including optical fibre cables for the transmission and distribution of electricity, communication signals
and data signals.
Design - includes the collection of information, resolution of conflicts with all affected parties, detailing of service location or position and
specifications and obtaining the written agreement of all affected parties.
Duct - an enclosed tubular or rectangular conduit for enclosing wires, pipes or cables for the purpose of providing structural or other protection
for the wires, pipes or cables and/or allowing for their installation or replacement without re-excavation, jacking or boring.
Equipment - pipes, cables, poles, manholes, transformers and other components that are a necessary part of a service system or subsystem.
Footway (Footpath/Sidewalk/Walkway) - a formally constructed area or paved strip within a road reserve for the safe passage of pedestrians,
animals and non-motorised transport. The terms footpath, sidewalk or walkway are also used with sidewalk generally used where the facility is
contiguous to the carriageway/roadway. A footway excludes surfaced or unsurfaced road shoulders.
Known Existing Service - any existing service on site that is shown on the drawings, detailed in the Contract Documentation, indicated on the
record (as-built) drawings or indicated in the wayleave information or which can be reasonably confirmed or inferred from visible features on site
shall be defined as known existing services. All new or relocated services, once installed by either the Contractor or any other party, shall be also
be defined as known existing services. All services located, identified and verified during any investigations for services on site shall be defined
as known existing services as soon as their presence on site has been detected. Any service which has been temporarily taken out of service to
allow for the execution of the works or which has been taken out of service, as a result of an event which necessitated the execution of the works,
shall also be deemed to be a known existing service.
Non-motorised transport (NMT) - non-motorised transport or transport by any means other than a motor vehicle including, but not limited to,
walking, cycling and animal-drawn vehicles and wheelchairs.
Pavement layers (Pavement layer works) - refer to Clause A4.1.2 of Chapter 4.
Pipe - a structural tubular product designed, tested, and manufactured for conveying liquids and gases under specific conditions.
Relocation - the removal of existing equipment and its re-installation in an alternative location. Such relocation may include the replacement of
some, or all, of the existing equipment as part of the relocation process.
Replacement - the removal of existing equipment that has been damaged, or is worn, or obsolete, and installation of a similar or improved element
of a service system or subsystem.
Reinstatement - the work necessary to replace, repair or otherwise restore all surfaces and features in a road reserve to the same or better
condition as existed prior to any construction activities that affected the original condition.
Road - a street, road, or other public way, as well as bridges or other structures, including shoulders, and footways designated for the purpose of
vehicular traffic and/or pedestrian and other non-motorised transport.
Road Authority - the authority responsible for a road in terms of the relevant national, provincial or municipal legislation.
Road (or Street) Furniture - a collective term for objects and pieces of equipment installed on streets and roads for various purposes. It includes,
but is not limited to, guardrails, traffic barriers, bollards, traffic lights, road signs and street lighting.
Service(s) - the plant, equipment, conduits or other infrastructure installed for the generation, supply, distribution, transmission, transportation,
storage or disposal of electricity, signals or data, liquids or gasses for the consumption, use or other benefit of others.
Service Owner - a private company, public authority, municipal council business unit, agency, directorate, or department etc. responsible for
providing a service, including but not limited to gas, petroleum products, steam, chemicals, electric power, data, communications, water, sewerage,
drainage or irrigation.
Sleeve - as for Duct.
Trenchless Methods - the methods of installing a pipe or sleeve under a road without disturbing the surrounding surface medium by using grade
and alignment control equipment. Methods covered by this definition include, but are not limited to, pipe jacking, micro-tunneling, ramboring (RB)
or directional drilling (DD) methods.
Verge - the area between the outer edge of the Road Prism, as defined in Clause A5.1.2 of Chapter 5, and the boundary of the road reserve.
A2.1.3 GENERAL
For the purposes of Clause A2.1.3 the definition of Services under Clause A2.1.2 shall be deemed to include any pipes, culverts or other
infrastructure provided for surface or subsurface drainage purposes.
A2.1.3.1 Installation of new services

New services shall be installed in accordance with the details provided in the Contract Documentation or as directed by the Engineer and in
accordance with the conditions and requirements of any applicable wayleaves or construction permits. Where sufficient details are not available
for the Contractor to plan and carry out the work the Contractor shall, in writing, request that the Engineer provide any outstanding details.
When the investigation of the existing services as described in Clause A2.1.3.2 hereafter has been completed the Contractor shall inform the
Engineer if the Contractor has become aware of any possible conflicts between the new proposed services and any known existing services.

a) Existing as-built records
The Employer will, on the drawings or otherwise in the Contract Documentation, provide information regarding the location of all known existing
services.
Although every care has been exercised in the compilation of the available as-built information, data, records and drawings for the known existing
services, the Employer does not guarantee, or accept responsibility for, the accuracy or completeness of the information provided. The Contractor
shall therefore locate, identify and verify all known existing services and at the same time investigate, locate, identify and report the existence of
any other services not previously known to be present on site.
b) Location of existing services
Before any work can commence the Contractor shall verify the actual position of each known existing service and bring to the attention of the
Engineer any previously unknown service that is not recorded in the existing as-built or wayleave records or indicated in the Contract
Documentation.
The Contractor shall comply with the specified wayleave processes and conditions of the relevant road or service authorities including where such
processes or conditions include a requirement to locate and verify the positions of services. If no other location and verification process is
applicable the process specified hereafter shall apply.
Owing to the possible inaccuracy of the records of existing services the Contractor shall carefully check, determine and verify on the site the
positions of all known existing services shown on the wayleaves, drawings or described in the Contract Documentation. This shall be done by
visual inspections, using appropriate detection equipment with acceptable accuracy, and by making excavations to expose the position of the
services at critical points. This shall also be done where no services are shown on the drawings or described in the Contract Documentation but
where such services are nevertheless believed to be present or the possibility of their presence can reasonably be inferred or expected by an
experienced and competent Contractor. Where indicated in the Contract Documentation services shall be detected by means of appropriate
Ground Penetration Radar (GPR) or other specified equipment. The Contractor shall propose the nature and extent of the services investigation
required and submit it to the Engineer for review and to obtain agreement on the use of any specialist services provided by other parties and on
any other related payment matters.
The horizontal and vertical positions of all services detected shall be marked carefully, surveyed and then shown on the drawings together with
appropriately recorded details of the service number, type and size.
The position of the existing services shall be checked and verified in advance of the construction works so that the Engineer is able to confirm or
make the necessary arrangements for the protection, removal or relocation of the services before work has to commence in their vicinity. The
lead times required to make the necessary arrangements for the protection, removal or relocation of services which the Contractor shall allow
shall be as indicated in the Contract Documentation or as stated in any applicable wayleaves or construction permits or as confirmed by the
Engineer and shall be as agreed with each affected service owner.
As soon as any service which has not been identified and located as described above is encountered on, under, over or within the site during
excavation or any other construction activity during the progress of the works, it shall henceforth be deemed to be a known existing service and
the aforesaid provisions pertaining to locating, verifying and recording its position shall apply. The Contractor shall notify the Engineer immediately
when any such service is encountered or discovered on the site. The relevant service owner shall also be notified of any services verified on site
that were not indicated on the original as-built records referred to in Clause A2.1.3.2a).
All the verified services will be defined as “known existing services” and the Contractor will be held responsible for any subsequent damage to
them whether caused directly by the Contractor’s operations or by the lack of proper protection. The Contractor shall take all reasonable
precautions not to damage the services during a search. If a service is damaged during the course of its location, discovery or exposure, the
Contractor will be reimbursed for the cost of making good such damage, unless it is established by the Engineer that the Contractor did not
exercise reasonable diligence and care and that the damage was avoidable.
Payment for the location and verification of existing services will be made in accordance with the relevant payment items in Section C2.1.
c) Condition of existing services
The Contractor shall acknowledge that he has inspected and examined all known existing services and all existing services subsequently
discovered on site and is satisfied that all such services were in an acceptable and serviceable state at the commencement of the works, or
alternatively, upon verification thereof as contemplated in Clause A2.1.3.2b). The Contractor shall report all services that are damaged or not in
an acceptable and serviceable state to the Engineer.
In the event of a dispute as to the acceptability and/or serviceability of an existing service at the commencement of the works or upon the
verification of such a service, the Contractor shall prove to the satisfaction of the Engineer that the service in question was not in an acceptable
and/or serviceable state at the commencement of the works or when located.
d) Protection of services
(i) Service owners
Prior to commencing work, the Contractor shall confer with all service owners, authorities and departments concerned and obtain the
necessary wayleaves, permits or permissions for both overhead and underground services affected by the works and shall satisfy
himself that all the relevant information required to complete the contract has been obtained. Refer to Clause A2.1.3.8 in this regard.
The Contractor shall carry out the works with minimum interference to existing services. The Contractor shall co-operate with all the
service owners, authorities and departments concerned and shall be responsible for timeously informing all service owners, authorities
and departments as to the planned date for the stage of the construction which involves the laying and/or relaying of any particular
services. The notice periods or lead times that the Contractor has to give each of the relevant service owners for them to be able to
lay and/or relay any particular service shall be as indicated in the Contract Documentation or confirmed by the Engineer and shall be
as agreed with each affected service owner.
The Contractor shall set out the lines and levels of kerbs, pipes, culverts and any other necessary features of the contract in order
that service owners, authorities and departments are able to lay and/or relay services correctly.
The Contractor shall allow all reasonable access to any service owner, authority or department for the purpose of maintaining, laying
and/or altering any services during the construction period as ordered by the Engineer and approved by the Employer.

(ii) Protection
During the course of the works all known existing services including traffic signals, water mains, sewers, electricity transmission and
communication lines, cables, poles, pipes and ducts as well as any storm water or drainage infrastructure, whether in service or not,
shall be protected, supported and maintained to the satisfaction of the service owner, authority or department concerned and the
Engineer.
The Contractor shall take all reasonable precautions and shall exercise due care and diligence to locate and protect known existing
services and to ensure that any interference with other underground or visible services are limited and controlled during any
construction activities including trenching, during the installation of services or during the relocation of services. Where protective
measures involve the construction of permanent work, the Contractor shall execute the work in accordance with the details shown or
described in the Contract Documentation or in accordance with the Engineer's instructions, and payment shall be made under the
relevant payment items. Hydrants under pressure, water main valve covers and manholes shall be kept unobstructed and accessible
at all times if they are in service. The covers and frames of service manholes and catch pits will have to be adjusted where they are
affected by the works.
The Contractor shall comply with the requirements of Clause A1.2.3.13 of Chapter 1 regarding work which involves blasting or the
use of heavy vibratory or impact compaction equipment near known existing services.
Unless otherwise instructed by the Engineer, no services shall be left exposed after their exact position has been determined and all
excavations carried out for the purpose of exposing underground services shall be promptly backfilled and compacted after surveying
and recording is complete.
Services which are left exposed with good cause shall be suitably protected from damage and in such a manner as will eliminate any
danger arising therefrom to the public and/or workmen, all in accordance with the requirements of the prevailing legislation and related
regulations.
Where known existing services, which include new services that are being installed, are left exposed or are left partially bedded or
backfilled, the Contractor shall provide adequate security measures to, as far as is reasonably possible, eliminate the risk of loss or
damage due to theft or vandalism. The Contractor shall ensure that the bedding and backfilling for services is completed without any
delay after a service has been laid to reduce the period that the services are exposed.
Survey beacons or reference pegs shall not be removed or disturbed. If such a need arises, the Engineer shall be advised so that
the Engineer can determine what suitable action is to be taken.
(iii) Damage
The Contractor will be held responsible for any damage caused by him to known existing services, anywhere along the entire lengths
of their routes, as may reasonably be deduced from the actual locations at which their positions were verified in accordance with
Clause A2.1.3.2b), due cognisance being taken of such deviations in line and level which may reasonably be anticipated, unless the
Contractor can prove that reasonable diligence and care had been exercised and that the damage was unavoidable despite all
precautions. The Contractor will be not be held responsible for any damage caused if the position of a known existing service deviated
by more than 1,0 m horizontally or 0,5 m vertically from the position as may reasonably have been determined after the location and
verification of the service’s position in accordance with Clause A2.1.3.2b).
In the event of damage to any services the Contractor shall immediately inform the Engineer, or when this is not possible, the relevant
service owner, authority or department, and obtain instructions as to the necessary repairs or protective measures to be taken and as
to who should carry out such repair or protection work. The Contractor shall take such immediate action as is necessary to prevent
further damage or danger to life or property. In urgent cases, the Contractor shall take appropriate steps to mitigate damage to and
interruption of the service. All known existing services of any nature whatsoever damaged as a result of the Contractor's operations
shall be repaired and reinstated forthwith by the Contractor or by the service owner, authority or department concerned to the
satisfaction of the Engineer and the relevant service owner, authority or department and the Contractor shall, subject to the provisions
of the preceding paragraph of this Clause A2.1.3.2d)(iii), be liable for any related costs.
(iv) Relocation
Whenever services are encountered which interfere with the execution of the works, and which must be moved and relocated, the
Contractor shall advise the Engineer, who will determine the extent of the work, if any, to be undertaken by the Contractor in moving,
relocating and reinstating or protecting such services.
It shall be clearly understood that, in certain instances, existing services can be relocated only after the Contractor has advanced
sufficiently on, or has completed, certain sections of the works included in the contract.
The Contractor shall work in close co-operation with all service owners, authorities or departments controlling services which have to
be protected, moved or relocated. Details regarding the state of negotiations concluded between the Employer and the service owner
prior to the commencement of the contract in respect of the time when either the service owner is prepared to start moving such
services or when the Contractor is required to, or will be allowed to, start moving the services, and the duration of such operations,
will either be stated in the Contract Documentation or be made available to the Contractor. Should the owners of services refuse to
co-operate with the Contractor in a reasonable manner in connection with the protection or moving of services belonging to them, the
Contractor shall refer the matter to the Engineer.
If the Contractor is not authorised to remove, relocate or replace services the Contractor shall give notice, in writing to the relevant
service owner, that the services on the site will require removal or protection prior to works being carried out in the vicinity of such
services. The Contractor shall advise the service owner of the number of services and their locations and the proposed dates when
work will commence in the vicinity of each service.
The Contractor shall give notice as follows:
• Where the details of the services to be relocated are provided at the commencement of the contract the Contractor shall send
the notice to the relevant service owners within fourteen days of the commencement of the contract.
• Where the need to relocate a service only becomes apparent after the location and verification of services has been completed
as required by Clause A2.1.3.2b) the Contractor shall send the notice to the relevant service owners within fourteen days of the
Engineer confirming that the service, as located or discovered, has to be relocated.
In addition to the above notice, the Contractor shall give the service owner a minimum of fourteen calendar days written notice (unless
a longer period has been included in the service owner’s wayleave or construction permit conditions in which case the longer period

shall apply) of the intention to commence work in the vicinity of each relocated service. Upon completion of the work in the vicinity of
each service, the Contractor shall notify the service owner, in writing, that work is complete.
Payment to service owners for the relocation of existing services or for any deposits or guarantees required by service owners for
work near services will be made in accordance with the relevant payment items in Section C2.1. The Contractor is responsible for
obtaining the relevant invoices when such payments are to be made and shall make any payments, due to the service owners, within
seven (7) calendar days of receiving an instruction from the Engineer to proceed with such payments.
A2.1.3.3 Safety, Method Statements, safeguarding the works and accommodation of traffic
a) Safety and Method Statements
All installation of services work shall comply with the health and safety requirements of Clause A1.2.3.6 of Chapter 1 and as specified in the
The Contractor shall prepare and submit to the Engineer for review and approval as required, the Method Statements required in terms of the
relevant health and safety legislation, the specification or the Contract Documentation. Construction Method Statements shall include, but not be
limited to, those indicated in Table A2.1.3-1.
Table A2.1.3-1: Method Statements
Section / Clause Activity to be Covered by Method Statement
A2.1.3.1 Installation of all new services
A2.1.3.2b) Location of existing services
A2.1.3.2d) Protection of services
A2.1.3.4 Protection of existing road carriageways, footways, verges and other infrastructure
A2.1.7.1 excluding Trenching for services

A2.1.7.1l) and A2.1.7.1r)
A2.1.7.1l) Timbering and shoring
A2.1.7.1r) Dealing with water
A2.2.7 Installation of ducts
A2.3.7 Installation of sewers and water mains
A2.4.7 Installation of cables
b) Safeguarding the works

The Contractor shall ensure that the works, including but not limited to all excavations that are accessible to the public, are kept safe at all times
in accordance with the requirements of the relevant legislation. Safety precautions shall include, but shall not be limited to, suitable barriers,
barricades or fencing, the provision of watchmen and the provision of suitable lighting at night as accepted by the Engineer. Payment for the
safeguarding of the works shall be in accordance with the relevant sections of the specification.
c) Accommodation of traffic
Traffic accommodation during the installation of services shall comply with the requirements of Section A1.5 of Chapter 1 and shall be as specified
in the Contract Documentation. All traffic accommodation measures shall be in accordance with the traffic accommodation plan for the works.
In addition to the accommodation of vehicular traffic the Contractor shall provide safe uncluttered thoroughfares for pedestrians and other NMT
(as may be applicable) and also comply with any other specific access or accommodation requirements provided in the Contract Documentation.
A2.1.3.4 Protection of existing road carriageways, footways, verges and other infrastructure
Before construction equipment for services related work is allowed onto surfaced road carriageways or paved footways or verges, the Contractor
shall submit, for acceptance by the Engineer, the proposals of how the Contractor intends operating construction equipment without causing
damage to any of the existing surfaces. Protection proposals may include the following:
• The use of gravel, wood, tyres, etc. as ramps where kerbs have to be negotiated;
• The use of tyres and rubber mats where crawler-tracked equipment is used;
• The placing of wooden blocks under the hydraulic stabilising arms of excavators or cranes etc.;
• The placing of wooden blocks under the tined buckets of excavating equipment when fully lowered; and
• The use of loading equipment fitted with buckets without tines to remove dumped material to a minimum of 200 mm above any paved
surface with the remaining 200 mm of material removed by means of hand work.
The Contractor shall adhere to the accepted proposals and will be held liable for repairing the damage caused by construction equipment or
activities to any surfaced roads, footways or verges or kerbing etc. and restoring them to their original condition.
Before any construction commences the Contractor shall submit, for acceptance by the Engineer, the proposals regarding how the Contractor
intends to work in the vicinity of any existing infrastructure or road furniture (such as traffic barriers, bollards, traffic lights, traffic signs, fencing,
stays and struts for poles and gantries and street lighting) without causing damage to the existing infrastructure.
A2.1.3.5 Programming for services

a) Trenching and installation sequence
Where services including ducts or pipes are to be installed at a level lower than the final level of any mass earthworks that have to be carried out
for the purpose of constructing a structure or a road, the trenching for such services, ducts or pipes shall be carried out after the mass earthworks

have been completed unless otherwise specified in the Contract Documentation or agreed by the Engineer. Refer to Clause C1.1.2.2d) of Chapter
1 in this regard.
Where services, ducts or pipes are to be installed across or along new roads that are under construction, such work shall be completed before
the subbase layer is constructed.
b) Programme and delays
When the Contractor prepares the construction programme, the Contractor shall clearly indicate the proposed start and end dates for the moving
of each known existing service or when a service owner will be required to start and conclude the moving of each service. Such scheduling shall
include reasonable periods for all such activities and shall take in to account any applicable conditions stated in wayleaves or construction permits
or as otherwise agreed with service owners. The Contractor shall update the construction programme, on at least a monthly basis, to reflect the
actual progress on the scheduled service work activities. If the Contractor considers that the progress of the works is being affected by the failure
of any service owner, authority or department to protect, lay, remove or relocate any service in time or in accordance with construction programme
and that a delay in the completion of the work may result, the Contractor shall immediately notify the Engineer in writing. The Contractor shall
take appropriate steps to accommodate or mitigate the effects of such delays irrespective of the cause of the delays. Should such delays make
it impossible to adhere to the programme of work, the Contractor shall, as agreed by the Engineer, suitably revise the programme in consultation
with the Engineer so as to limit, in so far as is possible, the extent of any resultant damages or delays.
If the location of services process, described in Clause A2.1.3.2b), results in the identification of further existing services, the Contractor shall, as
agreed by the Engineer, revise the construction programme to take account of any impact, as agreed with the service owner and the Engineer,
the recently located services might have on the completion of the works.
The Contractor shall keep detailed records of all dealings with service owners so that, if required, it can be demonstrated that every effort had
been made to timeously request and/or apply for the protection, removal or replacement of any services.
A2.1.3.6 Provision of record drawings and details

The Contractor, in addition to the records of the positions of known existing services, as determined in accordance with Clause A2.1.3.2b) above,
shall ensure that the horizontal and vertical positions of all new and relocated services installed are accurately recorded and shown on the record
drawings. All such drawings and records shall be delivered to the Engineer before the completion of the works. The position of the services shall
be determined by a survey carried out by a suitably qualified surveyor. If so specified in the Contract Documentation the surveyor shall be
registered as a Professional Surveyor, Technologist Surveyor or Technician Surveyor with the South African Council for Professional and
Technical Surveyors (PLATO). The survey required to accurately record the position of the services may have to be carried out before any
services are covered up. The position and levels of all manholes, valves, chambers, junction boxes, markers etc. shall be surveyed for the
completion records.
A2.1.3.7 Construction supervision

The Contractor shall ensure that all work related to services is carried out, executed by and supervised by appropriately and sufficiently qualified
and competent employees or agents.
A2.1.3.8 Liaison with affected parties

The provisions of Clause A1.2.3.22 of Chapter 1 shall apply to any wayleaves and/or construction or work permits required for all services related
work.
A2.1.3.9 Limitations and restrictions

a) Work near other or existing services
No work using mechanical trenching equipment shall be undertaken closer than 1,0 m from any existing cable, pipe or duct without the explicit
approval of the Engineer and the respective service owner.
Where any applicable wayleave conditions or construction or work permits include other working restrictions, limitations or conditions associated
with particular services or other infrastructure they shall become applicable to all such work under the Contract and supersede the restriction
stated in the paragraph above.
b) Maintaining accesses
The Contractor shall be responsible for maintaining accesses over trenches where applicable, in which regard the Contractor shall comply with
the relevant requirements of Section A1.5 of Chapter 1.
c) Installation under special conditions
The following conditions are defined as special conditions for the installation of services and must be treated in accordance with the site or contract
specific Contract Documentation, the wayleave conditions or any other relevant authority conditions as may be applicable in each case.
• Excavation within a radial distance of 500 mm from a power cable.
• Excavation requiring rock blasting.
• Placements requiring augering or horizontal directional drilling (HDD).
• Crossing of railway servitudes.
• Excavation adjacent to or crossing major road cuttings or embankments.
• Excavations near bridge abutments or footings.
• Work involving attachments to bridges or other structures.
• Concrete encasement of ducts in high risk areas.
• Installation of services in active clay conditions.
• Installation of services in areas where specific geotechnical conditions occur i.e. areas underlain by dolomites, collapsing soils or
dispersive soils etc.
d) Other conditions
Trenching at the toe, crest or through cut or fill embankments shall be done such that the slope stability of the cut or fill embankment is not
compromised.

e) Working widths
The Contractor shall always only occupy such areas as required to execute the specified services related work.
Where required by the Contract Documentation, once the setting out and pre-marking of the trench line has been completed, a corridor of a
suitable maximum width, as agreed by the Engineer, shall be allowed for all trenching operations i.e. for all safety and environmental protection
measures, accommodating workers and working space, as well as the safe placement of excavated material.
Where trenches are to be made in road reserves, servitudes or designated areas of specified width, the Contractor shall confine all his construction
activities to within the limits of such reserves, servitudes and widths unless permission to encroach on to the adjacent property has been obtained,
in writing in advance of any work, from any affected owner, lessee or occupier.
Any affected owner, lessee or occupier shall be afforded a reasonable time to remove any tall trees, shrubs or other plants as well as any
improvements from a servitude should the affected party wish to do so. No trees or shrubs shall be removed by the Contractor without the written
permission of the Engineer.
A2.1.3.10 Setting out of services works

The Contractor shall be responsible for the true and proper setting out of all work required for the installation of services and for the correctness
of the position, levels, dimensions and alignment of all parts of such works and for the provision of all necessary instruments, equipment and
labour in connection therewith.
The checking of any setting-out or of any line or level by the Engineer shall not relieve the Contractor of his responsibility for the correctness
thereof. The Contractor shall rectify any error in the positions, levels dimensions or alignment of the works.
Refer to Clause A1.2.7.2 of Chapter 1 in this regard.

A2.1.4.1 Temporary works
The temporary works relating to services shall be designed and installed by the Contractor as required to construct the permanent works specified
in the Contract Documentation or ordered by the Engineer. Where sufficient details are not available for the Contractor to design and carry out
the temporary works the Contractor shall, in writing, request that the Engineer provide any outstanding details.
A2.1.4.2 Alternative designs

Alternative designs, relating to the installation of services, that promote innovative and new technologies and reduce total life cycle costs or reduce
construction time or improve safety and provide an end product of similar or better quality and durability to that specified, may be offered.
Any alternative design shall comply with the same design requirements as the original design as detailed in the original Contract Documentation.
a) Pricing of alternative designs
For alternative designs to be considered they must be priced together with the original design. Any cost saving in relation to the original design
must be shown.
A detailed total cost of ownership, over a period of 20 years, calculated for the original as well as the alternative designs must be presented with
the alternative design.
b) Alternative design approvals
If an alternative design proposal is accepted in principle and is to be considered for approval the following shall be submitted with any proposed
alternative design:
• A detail design report by an Engineering Council of South Africa (ECSA) registered Professional Engineer which demonstrates that the
alternative design complies with the same design requirements as the original design included in the Contract Documentation;
• Method statements for alternative construction methods;
• All technical data sheets for alternative materials;
• Detailed life cycle cost of ownership calculations;
• Detailed construction program (integrated with the overall contract programme) and
• Any other information the Employer, Engineer or designer deems necessary.
All alternative designs for services will have to be accepted by the Employer in writing before the Contractor may commence with the construction
according to the alternative design.
c) Alternative design responsibility
Although the alternative design will be evaluated by the Employer or his representative, the professional liability for such designs shall remain with
the Contractor. The conditions and liabilities associated with the professional liability for designs shall be stated in a written agreement between
the Contractor and the Employer should any alternative designs be accepted.
A2.1.4.3 Designs
Where the Contractor is responsible for the design of the civil engineering component of any service installations which form part of the permanent
works in a road reserve, as may be specified in the Contract Documentation, such work shall be carried out by sufficiently qualified and competent
registered professional civil engineers.
Any such designs of the permanent works by the Contractor shall be submitted to the Employer for acceptance before any construction of the
designed work may commence. Although the designs will be evaluated by the Employer or his representative, the professional liability for such
designs shall remain with the Contractor.

A2.1.4.4 Design criteria for trenches in verges
Design proposals, where these are to be provided by the Contractor, for service trenches in verges shall ensure that the completed and reinstated
trenches in unpaved road verges:
a) Must be able to resist a load of 70kPa i.e. equivalent to the load of a tractor pulling a grass-cutting machine or;
b) Must have a bearing strength equivalent or better than the adjacent undisturbed material whichever is the highest.
The above criteria will not apply in the case of a trench in steep slopes (slopes exceeding 1:3 V:H) either in fill or cut, marshy clayey areas or in
the vicinity of structural elements such as road signs, fence lines, telephone poles etc. where appropriate specific designs shall be prepared and
submitted to the Engineer for acceptance.
A2.1.5 MATERIALS
A2.1.5.1 Trench backfill material
Backfill for ducts, pipes or cables installed by methods other than by micro or mini trenching, unless otherwise specified in the Contract
Documentation, shall be a material that:
• Contains no detectable deleterious, organic or hazardous waste material.
• Can be placed without significant voids.
• In areas not subject to vehicular traffic loads has a maximum aggregate size of 100 mm and complies with the requirements for a G9
material in terms of Table A4.1.5-3 in Clause A4.1.5.6 of Chapter 4.
• In areas subject to vehicular traffic loads has a maximum aggregate size of 75 mm and complies with the requirements for a G7 or G8
material as specified in Table A4.1.5-3 in Clause A4.1.5.6 of Chapter 4.
• Can be compacted in accordance with the requirements of Clause A2.1.8.2.
A2.1.5.2 Soil cement and stabilised trench backfill material

a) Soil cement backfill
Soil cement material shall consist of an approved soil or gravel mixed, by hand or by means of a suitable concrete mixer, with 3 to 6 % by mass
of cement of an agreed class and type, as instructed by the Engineer, and only sufficient water to give it a consistency that will permit the soil
cement to be placed, with the use of vibrators or other compactors, to properly fill all voids between the ducts or pipes and the sides of excavations.
The material used for soil cement shall be, as indicated in the Contract Documentation, either a type G5 gravel or crushed stone material or a
type G7 or G8 sandy material (all types as specified in Section A4.1 of Chapter 4), which may contain larger particles up to a maximum size of
37,5 mm and have a plasticity index not exceeding 10. Material including silt or clay shall not be used and the material used shall be obtained
from a source approved by the Engineer.
b) Cement stabilised backfill
Backfilling shall, where directed by the Engineer, be stabilised with 3 to 6 % by mass of cement of an agreed class and type, as instructed by the
Engineer. The material stabilised shall be, as indicated in the Contract Documentation, either an approved type G5 gravel or crushed stone
material or a type G7 or G8 soil or gravel material (all types as specified in Section A4.1 of Chapter 4) which may contain larger particles up to a
maximum size of 37,5 mm and have a plasticity index not exceeding 10.
A2.1.5.3 Water
The requirements of Clause A1.2.3.21 of Chapter 1 shall apply to the use of water for all services work dealt with in Chapter 2.
Water used for the compaction of any backfill, fill blanket, bedding or layer works dealt with in Chapter 2 shall comply with the requirements of
Clause A4.1.5.18 of Chapter 4. For the purposes of Clause A4.1.5.18 of Chapter 4 backfill, fill blanket and bedding material shall be deemed to
be earthworks.
Water used for mixing concrete shall comply with SANS 51008. In addition, potable water used for concrete shall comply with the requirements
of SANS 241-1 for drinking water.
A2.1.5.4 Other material requirements for dry, wet and energy services
Other material requirements for dry, wet and other services shall be as specified in Clauses A2.2.5, A2.3.5 and A2.4.5.

A2.1.6.1 Excavation equipment
The Contractor may use trenching equipment that will excavate trenches to a width such that the side allowance does not exceed the appropriate
value specified in Clause A2.1.7.1h) by more than 50 %. Where, in terms of the Contract Documentation or of the drawings, the authorised (base)
width of a trench for a service, duct or pipe, or a portion of a service, duct or pipe, is not to exceed the minimum authorised (base) width or a
stated value, the Contractor shall use trenching equipment that will produce the required trench width or the Contractor shall accept responsibility
for all costs incurred in strengthening the relevant service, duct or pipe as required by the additional trench width used.
A2.1.6.2 Compaction equipment

The Contractor may use mechanical compaction equipment but the Contractor shall select such equipment and operate it in such a manner that
any service, duct, pipe or cable is not stressed or damaged. Machine compaction shall not be used directly above a service, pipe, duct or cable
until sufficient bedding, fill or backfill has been placed to ensure that machine compaction loads transmitted to the top of the service, pipe, duct or
cable are no greater than would be imposed by normal road traffic over the service, duct, pipe or cable with a cover of 600 mm.

A2.1.6.3 Other equipment requirements for dry, wet and energy services
The bedding and backfilling for ducts, pipes and cables shall be carried out with the construction equipment capable of fulfilling the specified
requirements taking onto account the relevant trench widths and depths.

A2.1.7.1 Trenching for Services
a) General
The Contractor shall carry out all trenching work in compliance with the relevant safety regulations and obligations in terms of the Occupational
Health and Safety Act. Refer to Clause A2.1.3.3 in this regard.
Trenching may be done either by hand or by using mechanical construction equipment or by a combination of hand trenching and mechanical
trenching subject to all other specified restrictions in this regard including those in Clause A2.1.3.9a).
b) Planning
All trenching operations related to services shall be planned and executed in accordance with the specifications and any wayleave conditions or
construction or work permit conditions.
Planning for trenching work shall be realistically reflected in the contract programme and should adequately address the risks associated with the
periods that trenches are left open before the installation of services and completion of the backfilling. The planning should also address all other
risks associated with trenching including impacts on access and on public vehicular and pedestrian traffic and the risks associated with flooding
etc.
c) Setting out of trenches
A suitable qualified surveyor shall be used for all setting out to ensure trenching is true to the design and/or wayleave condition lines and levels.
Where the setting out is determined by cadastral information a suitably qualified and registered professional surveyor shall be used to verify such
information on site.
d) Saw-cutting before excavation
Before excavations are made in an existing surfaced roadway or other paved areas, the width of the trench or such other width as may be agreed
on by the Engineer, shall be marked on the surface and the surfacing material or in situ concrete paving shall be neatly cut along the markings,
to avoid any overbreak of the surfacing or paving beyond the agreed limits. The saw-cutting equipment shall be capable of cutting the material in
a single operation without fragmenting the material, and in straight lines. Paving units (blocks or bricks) shall however not be cut but shall be lifted
as near as possible along the markings and stored for re-use. The cost of cutting and removing surfacing and paving material shall be measured
under the relevant payment items.
e) Clearing and grubbing
Once the excavation has been pre-marked to a suitable width, the surface shall be cleared to the extent determined by the proposed trenching
technique. Complete stripping of vegetation and top soil may not necessarily be required. The removal of large trees or tree trunks shall only be
considered under extreme conditions and shall only be done with the approval of the Engineer.
The removal of existing paved footways shall be undertaken to line and level with minimum damage to and edge breaking of any paving lifted,
using appropriate concrete or asphalt cutters. Paving slabs/blocks shall be removed for later re-use or reinstatement of paved surfaces, and all
spoil shall be removed from the work site, where applicable.
Paving blocks or bricks that are removed shall be neatly stacked on the side, at a minimum 750 mm distance from the edge of the excavation, for
later use during trench reinstatement. The paving shall be stacked so as not to fall over or prohibit any pedestrian or other NMT traffic and shall
not be mixed with the excavated material from the trench.
f) Safe placement of excavated material
All excavated material shall be placed adjacent to the excavated trench provided it can be done while ensuring the safety of the excavation.
Material shall be placed at a distance from the lip/edge of the excavation determined by the Contractor. In order that no back spillage of excavated
material is possible into the trench the distance from the lip/edge of the excavation to the excavated material shall be at least 750 mm.
In areas with limited working widths the Contractor shall compile a method statement for the accommodation of excavated material for acceptance
by the Engineer. At no time shall any excavated material be placed in any way as to endanger the flow of any vehicular or pedestrian or other
NMT traffic.
Where excavated material cannot be temporarily placed alongside the excavation, the material shall be stockpiled in accordance with the
requirements of the Contract Documentation.
g) Digging of pilot holes for the location of services
Once the line for the trenching has been set out and marked, pilot holes or trial pits shall be excavated by hand to the specified depth and at
intervals of not more than 10 m (unless another interval is agreed by the Engineer) in order to confirm soil conditions and to verify the positions of
other services.
h) Excavation
Unless otherwise specified or shown on the drawings, the width of trenches for services, other than cables, shall be the authorised trench widths
as determined below and these will be used to calculate the quantities of material excavated. Excavation at widths in excess of these
predetermined widths will not be measured for payment and excavations narrower than these widths will only be allowed with the written approval
of the Engineer. Also refer to Clause A2.1.6.1 in this regard. The trench widths for the installation of cables shall be in accordance with Clause
A2.4.7.2b)(i).
The authorised trench width shall, irrespective of the type of service (excluding cables) and the type of bedding or floor slab, be determined by
the following formula:

W = B + 2S where;
W = The authorised width.
B = The outside diameter / width of the service (duct or pipe etc). No allowance shall be made for the additional diameter or width
of collars, joints or couplings.
S = The side allowance to provide the working space on each side of the service measured between the external surface of the
pipe or duct and the side of the trench.
Unless otherwise indicated in the Contract Documentation, S shall be as follows:
Table A2.1.7-1: Side allowance for excavation
Outside Diameter of Service (B) mm Side Allowance (S) mm
Up to 250 200
Greater than 250 and up to 700 300
Where two or more pipes are to be placed in a trench the authorised width (W) shall not be less than the sum of the external diameters / widths
of the pipes plus the side allowance for each of the outer pipes plus, between each pair of adjacent pipes, the average of the side allowance for
each pipe. For the installation of more than one duct in a trench refer to Clause A2.2.7.2a).
The minimum authorised width (W) for ducts or pipes of outside diameter not exceeding 125 mm and laid to a depth not exceeding 1,5 m may be
less than 400 mm for flexible continuous ducts or pipes that, in terms of the specification, do not require bedding or jointing and provided that the
backfilling can be compacted in accordance with the requirements of Clause A2.1.8.2.
Where ducts or pipes are to be encased in concrete or soil cement the trench width shall be determined either by the width of the encasement, or
as indicated in the Contract Documentation or as instructed by the Engineer.
The Contractor may slope the trench sides or bench the trench from a point above the top of a duct or pipe in compliance with the relevant safety
regulations and obligations at his own cost.
The depth of excavations shall be as specified in the Contract Documentation or as indicated by the Engineer on site. Trenches for water pipes
shall, unless otherwise specified, be excavated at a constant depth to follow the general surface contours wherever possible.
Trenches shall be neatly trimmed to line and level. The Contractor shall maintain the correct line and grade throughout the work. Trenches shall
be straight along the centre line and between pegs, where applicable. Between pegs the trench bottom shall be carefully graded and tested by
sight rails and boning rods or other means.
Trenches shall, except where otherwise indicated or permitted, or in the case of a statutory safety requirement, be excavated with vertical sides
without any undercutting of the sides.
The cost of trimming excavations by hand or machine shall not be paid for separately but shall be included in the rates tendered for excavation.
Should the Contractor for any reason whatsoever excavate beyond the limits of the authorised dimensions, the Contractor shall, at his own cost,
carry out the additional backfilling that will be required as a result of such excess excavation, and he shall use the same material that has been
used for the rest of the trench at the level in question. Where the trench has been excavated deeper than the required depth, the bottom shall be
reinstated to the correct level as specified for the applicable service.
i) Classes of excavation
Where mechanical excavation equipment is used the excavation of material in trenches shall be classified as follows:
(i) Hard Excavation
Hard excavation shall be excavation of material which will require breaking up before removal by one of or a combination of the
following:
• An excavator fitted with a hydraulic percussion hammer or fitted with a ripper,
• Hand operated pneumatic or electro mechanical equipment such as jackhammers or pavement breakers,
• Drilling and using non-explosive rock-breaking products such as injecting chemical expansion agents, or
• Drilling and blasting.
Excavation of individual large boulders, core stones and lumps of hard material in excess of 20 m3 shall also be classified as hard
excavation.
Any material where boulders, each exceeding 0,1 m3 in size, make up more than 40 % of the volume of the material will be classified
as hard material.
(ii) Stabilised Layers
All material which has been stabilised with any stabilising agent and requires careful cutting and excavation without damage to
surrounding existing road layers, by whatever method, shall be classified as stabilised material.
(iii) Soft Excavation
All material not classified as hard or boulder material or stabilised material shall be classified as soft material.
j) Excavation using Labour Enhanced Construction Methods
Where the planned use of mechanical excavating equipment is likely to cause damage to services, trees or property, the Contractor shall advise
the Engineer thereof, who may then instruct, in writing, that the excavations be made by means of labour enhanced construction methods and
paid under the relevant items for such excavation. However, no such instruction or payment will be required or applicable where the planned or

specified method of excavation, as indicated in the Contract Documentation, was by labour enhanced construction methods. Also refer to Section
B2.1 in this regard.
k) Excavations outside the normal trench profile
Excavations outside the normal trench profile, which are necessary for the removal of unsuitable material at founding levels, for accommodating
structures such as manholes, valve chambers, junction boxes, thrust blocks, draw pits, catchpits, wing walls or for accommodating any other
features, like the portion of sewer-house connections between the junction with the main sewer and its point of connection with the sewer from
the property, identified in the Contract Documentation, will be measured and paid for separately from trench excavations. These excavations may
be made by means of excavating equipment wherever practicable, or otherwise by hand, but will not be classed as hand excavation. Excavations
for handholes to accommodate pipe joints will not be included in payment for excavations outside the normal trench profile. Also refer to Clause
A2.1.7.1q) and Section C2.1.
l) Timbering and shoring
(i) Contractor’s Obligations for Shoring
The Contractor shall provide all the temporary shoring works required including all the timbering, strutting and shoring required in
terms of all the regulations and obligations applicable to the safety of the excavations and structures adjacent to excavated trenches.
The Contractor shall be solely and wholly responsible for the design of such temporary shoring works and for ensuring the adequacy
of the measures. Without in any way affecting or detracting from the Contractor’s responsibility, the Engineer shall have the right
to instruct the Contractor to provide additional or improved timbering, shoring or strutting where the Engineer considers this to be
necessary. The Contractor shall have no claim for additional payment on this account.
The shoring methods adopted shall be compatible with the soil type and the excavating, backfilling and pipe or duct laying methods
adopted and shall not place any undue restrictions on the laying of the ducts or pipes. The specified trench width shall be the neat
width between the timbering and shoring. Any extra excavations required for the timbering and shoring shall be included in the
rates tendered for excavations. The Engineer shall be informed when any timbering and shoring installed is to be removed.
As an alternative to timbering and shoring, the Contractor may, while complying with all the regulations and obligations applicable
to the safety of the excavations and where sufficient space is available and where the safety of nearby services and structures is
not jeopardized, elect to slope the sides of the trench from a point above the duct or pipe as mentioned in Clause A2.1.7.1h), and
the Contractor shall also make allowance for such additional work in the tendered rates for excavation and backfilling.
No separate payment will be made for timbering, strutting and shoring provided by the Contractor in order to comply with the
requirements of this Clause A2.1.7.1l)(i).
(ii) Contract Specific Shoring Requirements
Where specifically required in terms of the Contract Documentation timbering, strutting and shoring shall be provided to ensure the
stability of, or for the protection of, particular structures or services etc. Where such requirements are stated and described separate
payment will be made for the timbering, strutting and shoring under the pay items scheduled for such specific work. The Contractor
shall be solely and wholly responsible the design of such timbering, strutting and shoring and for ensuring the adequacy of such
measures.
The Engineer may instruct the Contractor to leave any timbering, strutting and shoring that has been provided by the Contractor in
accordance with Clause A2.1.7.1l)(i) permanently in place in an excavation. Where such timbering, strutting and shoring is
permanently left in place payment will be made under the relevant pay item.
m) Soil cement backfilling
Where specified in the Contract Documentation soil cement backfill shall be used for the bases of overhead service poles and anchor poles and
for any other type of backfill indicated.
n) Erosion protection with sandbags
Where indicated in the Contract Documentation or ordered by the Engineer sandbags shall be used in trenches to prevent the ingress of water
and / or erosion during construction of the completed works. The spacing and type of sandbags is a function of the slope of the trench and the
features of the catchment area and shall be in accordance with the details provided or as instructed by the Engineer.
o) Tunnels and bolsters
The Contactor shall be permitted to tunnel underneath obstructions such as trees, walls, etc., provided that the Contractor has obtained the
Engineer’s written approval, the trench is of sufficient depth, and the in situ material is suitable for tunnelling. No blasting shall be allowed for the
excavation of tunnels and bolsters. Tunnelling will not be paid for as hand excavation. The tunnel or bolster shall have the same width as the
trench and shall have a minimum vertical height of 1,2 m above the duct or pipe invert. Tunnels and bolsters shall be properly timbered and
shored where necessary. Where a pipe or duct passes through a tunnel or bolster, the pipe or duct shall, after having been tested, be encased
in concrete or soil cement material as instructed by the Engineer, after which the tunnel or bolster shall be filled with hand-packed rocks having a
maximum dimension of 300 mm. The rocks shall be so packed as to provide a minimum of voids. Voids remaining in the rock packing shall be
filled with dry sand, as the packing proceeds. Payment will be made under the applicable pay items in Section C2.1.
A tunnel with a length of 3,0 m or less shall be designated as a bolster and shall be paid for as an open trench, and a tunnel longer than 3,0 m
shall be paid for as a tunnel. The minimum distance between two consecutive tunnels or bolsters shall be 3,0 m.
p) Preparation of the bottom of trenches
Trenches shall be excavated to the required level as specified in the Contract Documentation.
Where trench bottoms consist of loose in situ gravel material, it shall be thoroughly compacted to a minimum of 90 % of MDD or a maximum DCP
penetration of 25 mm per blow for a depth of 75 mm to provide a firm floor.
Poor founding conditions may warrant over-excavating and reinstating the trench bottom in one of the following ways as instructed by the Engineer:
• Lining the trench bottom with an appropriate geotextile or
• Placing a layer of 37,5 mm concrete aggregate or
• Placing a selected backfill material compacted to a minimum of 90 % of MDD or
• Placing a layer of soil cement or
• Placing a layer of concrete.

Such reinstatement will not be paid for in the case of over excavation (overbreak) or where poor founding conditions have been caused by the
Contractor’s negligence.
Founding and trenching conditions in hard rock must allow for a selected material bedding with a minimum thickness of 100 mm. Trench bottoms
in hard material shall be cleared of all rock projections, rock fragments or particles of hard material.
The trench bottom shall be hand trimmed to final levels and grades immediately before bedding is placed or ducts or pipes are laid.
No separate payment will be made for the preparation of trench bottom except where the Engineer orders treatment of the trench bottom due to
poor founding conditions.
q) Excavations for pipe joints
If necessary, accurately located recesses shall be cut into trench bottoms to accommodate duct or pipe joints. Such recesses shall be properly
shaped and sized to facilitate jointing. Recesses for pipes to be welded together in the trench shall provide a clear space of not less than 0,5 m
below the pipes. Payment for making such recesses shall be included in the tendered rates for the supply, installation, joining and testing of the
various types of ducts or pipes and fittings.
r) Dealing with water
(i) Contractor’s obligations for dealing with water
The Contractor shall properly deal with and dispose of water to ensure that the trenching works are kept sufficiently dry for their
proper execution including the provision of adequate protection against flooding and damage by stormwater, flow from springs and
seepage of ground water. For this purpose the Contractor shall provide, operate and maintain in sufficient quantity such pumping
equipment, well points, pipes and other equipment as may be necessary, and he shall also provide any sumps, furrows, coffer-
dams, temporary berms and other temporary works as may be necessary to minimize damage, inconvenience or interference. The
Contractor shall be responsible for repairing, at his own expense, any damage to the works that may arise as a result of the
inadequacy of the protection provided. The Contractor shall comply with the requirements of Clause A1.2.3.19 of Chapter 1.
The Contractor shall plan his excavation work in such a way that the risks of flooding of trenches is properly addressed and, in
addition to the measures indicated above, such planning shall include limiting the lengths of open trenches and/or providing cross
embankments or bulkheads in open trenches as indicated below. In the case of a trench on sloping ground the Contractor shall
take adequate precautions to minimize erosion in the trench and adjacent ground from which vegetation has been removed.
If required by the Engineer, the Contractor shall leave portions of a trench unexcavated to prevent the flow of water down the trench.
These bulkheads shall be at least 1,0 m thick and shall be spaced as agreed by the Engineer. No additional payment over and
above the normal excavation rate will be made for leaving bulkheads temporarily unexcavated.
The Engineer may instruct the Contractor to provide a layer of aggregate below the bedding to serve as a drain to dispose of excess
water. The thickness of the layer shall be determined on site by the Engineer. The drainage layer shall be self-draining. Separate
payment will be made under the applicable pay items where such measures are ordered.
Separate pay items are included in Section C2.1 for complying with the general obligations of this Clause A2.1.7.1r)(i).
(ii) Contract specific requirements for dealing with water
Where specifically required in terms of the Contract Documentation water inflow shall be controlled using specified temporary works.
Where such requirements are stated and described separate payment will be made for the providing and operating the necessary
construction equipment under the pay items scheduled for such specific work.
In the case of trenches for sewer pipes, the Engineer may instruct the Contractor to install a subsurface drain below the bottom of
the trench. The position and details of the drain in the trench shall be as shown on the drawings or as determined by the Engineer
and payment will be made under the relevant pay item.
The Engineer may instruct the Contractor to install sand bag bulkheads to prevent the flow of water down trenches as indicated in
Clause A2.1.7.1n). Where such bag bulkheads are ordered payment will be made under the relevant pay item.
s) Use of soil cement and stabilised backfill material
(i) Soil Cement Backfill
The soil cement material, as specified in Clause A2.1.5.2a), shall be mixed on site by hand or by means of suitable concrete mixers.
The water and cement contents shall be carefully controlled during mixing. The material shall be placed and then thoroughly
compacted by means of concrete vibrators or other compactors so as to fill all the voids between ducts or pipes and the sides of
excavations.
Care shall be taken to anchor ducts or pipes in trenches to prevent any displacement or floating during the placement of soil cement
material and to prevent ingress of the soil cement material into the ducts or pipes etc.
(ii) Cement Stabilised Backfill
Sufficient water shall be added to cement stabilised material, as specified in Clause A2.1.5.2b), without saturating the mixture, to
achieve uniform mixing and compaction to a minimum of 93 % of MDD.
The processing, placing and compaction shall be completed within 6 hours from the time that the cement is first added to the
material.
t) Backfilling
Backfilling shall be deemed to be the material placed and compacted on top of the fill blanket or bedding, as applicable, to reinstate an excavated
trench. Backfill excludes the reinstatement of any pavement layers or surfacing which work shall be specified separately.
All excavated material from trenching operations, shall be treated as potential backfilling material and therefore neatly stockpiled along the
excavation and not allowed to be contaminated with toxic, oversized or organic materials or building rubble.
The backfilling shall be compacted in accordance with the minimum densities specified in Clauses A2.1.7.1s)(ii) and A2.1.8.2a) or in accordance
with the Dynamic Cone Penetrometer acceptance criteria in Clause A2.1.8.2c).
The placing and compaction of fill blankets and bedding material shall be carried out as specified in the relevant sections of these specifications.

Backfilling shall be done with approved excavated or imported material. Backfilling shall, in the case of ducts or pipes on a concrete bedding, not
be commenced before the concrete has attained a compressive strength of at least 75 % of the strength specified for the concrete. All backfill
material shall be compacted to the minimum densities specified in layers not exceeding 150 mm in compacted thickness unless otherwise agreed
by the Engineer.
A2.1.7.2 Reinstatement of existing roads and existing road furniture

a) General
Where services are installed in an existing road reserve, all paved areas, including road carriageways, sidewalks, footways and walkways and all
unpaved verge areas shall be reinstated in accordance with the details provided in the Contract Documentation or as directed by the Engineer.
Where sufficient details are not available for the Contractor to plan and carry out the work the Contractor shall, in writing, request that the Engineer
provide any outstanding details.
All drainage affected by any trenching processes, e.g. earth drains, concrete channels, stormwater pipes and subsoil drains shall be reinstated to
their original functionality.
All other road furniture or structures, e.g. fences, stays, struts, signposts and signs etc., shall be reinstated or repaired as required after completion
of the services installation work. Stay wires and struts on overhead services that were removed and temporarily supported shall be reinstated or
restored to their original condition. All reinstated works shall be recorded, photographed, and a register containing this information handed to the
Engineer to obviate potential future problems with authorities and/or land owners.
b) Reinstatement of existing road carriageways and other paved areas
The pavement layers and surfacing required to reinstate any road carriageways, sidewalks, footways and walkways affected by service
installations in existing road reserves shall be in accordance with the details regarding pavement layer and surfacing type, thickness, material
characteristics and compaction as provided in the Contract Documentation or ordered by the Engineer. The materials and construction required
for reinstatement work shall, as applicable, comply with the requirements of Chapters 3, 4, 5, 6, 9,10 and 11.
If the final base, asphalt or surfacing layers cannot be placed during the reinstatement of trenches across existing roads or other paved areas,
approved excavated material shall be used as backfill to the surfacing level, as a temporary measure, to enable the road to be opened to traffic
as soon as possible. This may only be done with the prior agreement of the Engineer. The temporary backfill shall be well compacted and
maintained until the temporary material is completely removed and the final layer/s are reinstated.
c) Reinstatement of road markings
After completion of any work in existing road reserves, the Contractor shall repaint the road markings that have been damaged or obliterated in
accordance with the requirements of Section A11.7 of Chapter 11. Payment for repainting of traffic markings will be made under the relevant pay
items for such work.
d) Reinstatement of unpaved areas
Unpaved areas in an existing road reserve affected by service installations shall be reinstated and finished in accordance with the details regarding
trimming, top-soiling, establishment of vegetation as provided in the Contract Documentation and in accordance with the requirements of Section
A11.8 of Chapter 11. Payment for reinstating unpaved areas will be made under the relevant pay items for such work.
A2.1.7.3 Railway reserves, bridge and other special crossings

Where services or ducts have to be installed across railway reserves, bridges or other structures or in any other special circumstances the work
for such crossings shall be carried out in accordance with the requirements of the Contract Documentation and in accordance with the applicable
sections of this specification.
A2.1.7.4 Alternative installation techniques

Instead of installing services using trenching other appropriate techniques and equipment may be considered during the installation of services
while ensuring compliance with the specified quality and workmanship requirements. Topography and geotechnical site conditions shall be taken
into account during the planning and programming for such work. If deemed beneficial and practical the Contractor may submit a proposed
alternative installation technique to the Engineer for acceptance.
The choice of equipment shall be based on the principle of limiting any adverse effect on the environment or damage to existing infrastructure.
Alternative installation techniques may include trenchless installation (e.g. pipe jacking, micro-tunneling, ramboring or directional drilling),
ploughing or the use of over-head structures.
A2.1.7.5 Trenchless methods

a) General
The installation of ducts or pipes using trenchless methods shall comply with the requirements of Section A12.7 of Chapter 12. Trenchless
installation shall be carried out by competent staff. Relevant certification of equipment operators and proof of competency shall be submitted to
the Engineer and kept available on site at all times.
b) Method Statements and designs
To ensure a well-designed and smooth trenchless installation operation, the Contractor shall comply with the requirements of Clauses A12.7.3.2
and A12.7.3.3 of Chapter 12, regarding the submission of method statements and, if applicable, comply with the requirements of Clause A12.7.4
of Chapter 12, regarding designs by the Contractor. An appropriate and comprehensive risk assessment shall be submitted with the method
statements.
c) Minimum Requirements during trenchless operations
The Contractor shall comply with the following during trenchless operations:
• An all-weather access to the sites at the entrance and exit positions of the trenchless operations shall be established and maintained.
• Catch pits shall be excavated at the entrance and exit points before any installation operations commence. These pits shall allow for any
drilling residue to be collected and reclaimed preventing spilling or wastage.

A2.1.7.6 Ownership, removal and disposal of existing service materials
In accordance with Clause A1.2.3.12 of Chapter 1 any existing service material (ducts, pipes, cables etc) recovered when existing services are
removed shall remain the property of the Employer unless otherwise stated in the Contract Documentation.
Existing services shall only be removed as indicated in the Contract Documentation or as directed by the Engineer. Prior to the removal of any
existing service the Contractor shall ensure that the service has been disconnected and that it can be safely removed. Payment for the removal
of services will be in accordance with the relevant pay items for excavation, removal and backfilling.
Where stated in the Contract Documentation the Contractor shall become the owner of specific recovered service materials and shall be
responsible for the disposal of the materials and for providing the Engineer with a full record of the disposal of the materials for control purposes.
Payment for the disposal of the materials will be in accordance with the relevant item in Section C2.1.
A2.1.8 WORKMANSHIP
The requirements of Clause A1.2.8 of Chapter 1 shall apply to the process and acceptance quality control for all services work dealt with in Section
A2.1.
The Engineer may, at his discretion, elect to use some of the Contractor’s process control test results if the Engineer is satisfied that the
Contractor’s process control requirements are acceptable for acceptance quality control purposes.
The requirements of Clause A1.2.3.14 of Chapter 1 shall apply to any remedial work required where any work or material does not comply with
the specified requirements.
The requirements of Clause A12.7.8.1 of Chapter 12 shall apply to the testing of any services installed using trenchless methods.
A2.1.8.1 Tolerances for trenches

a) Horizontal alignment, vertical alignment, grade and level
Any deviation from the specified horizontal alignment or level of the invert and the specified dimensions (widths) of a trench and (for a height equal
to at least the diameter of the service, pipe or duct, as applicable) of the lower part of the sides of a trench shall be such that the service, pipe or
duct may be laid and bedded in the trench within the tolerances specified for the service, pipe, duct or cable in Clauses A2.2.8.1a), A2.2.8.1b),
A2.3.8.2a), A2.3.8.3a) and A2.4.8.2.
b) General
Where trenches are deepened or widened to accommodate structures etc., as mentioned in Clause A2.1.7.1k), the tolerance limits of the
excavations shall be the same as those of the structures etc., in so far as invert level and plan position are concerned.
If no other tolerances are applicable the maximum horizontal deviation of the centre line of a trench from the specified position shall be 100 mm
and the maximum deviation from the specified invert level shall be 50 mm.
A2.1.8.2 Compaction
The method to be used for backfill and trench bottom compaction acceptance quality control shall be either relative density compaction control or
DCP compaction control as indicated below. If it is not clear which method is applicable to a particular situation, due to the conditions or
circumstances on site or due to any discrepancy in relevant information, relative density compaction control shall apply.
a) Relative density compaction control
Relative density compaction acceptance quality control shall be used for all areas except where DCP control is permitted as indicated in Clause
A2.1.8.2c). Relative density compaction control shall, in particular, be used under any road carriageways or lined drains or under any paved
footways, sidewalks or walkways or under any other area indicated in the Contract Documentation. Relative density compaction control shall be
used for trenches in embankments, fills or cut slopes unless DCP control is permitted in the Contract Documentation or as agreed by the Engineer.
(i) Areas not subjected to vehicle traffic loads
In areas not subjected to vehicle traffic loads (deemed to only include the unpaved verge of a road reserve) trenches and trench
bottoms shall be backfilled in layers of thickness (after compaction) that do not exceed 150 mm and the material shall be compacted
to a minimum of 90 % of MDD or a minimum of 100 % of MDD where sand (as defined for fill in Clause A4.1.5.9 of Chapter 4) is
used. The compacted material shall comply with the acceptance requirements indicated in Clause A2.1.8.2b).
(ii) Areas subjected to vehicle traffic loads or within the road prism
In areas subjected to vehicle traffic loads (deemed to include any road carriageways, lined drains or any paved footways, sidewalks
or walkways or any other areas indicated in the Contract Documentation) or within the road prism (deemed to include any fill or
embankment or any other areas indicated in the Contract Documentation) or on cut slopes, trenches and trench bottoms shall be
backfilled in layers of thickness (after compaction) that do not exceed 150 mm and the material shall be compacted to a minimum
of 93 % of MDD or a minimum of 100 % of MDD where sand (as defined for fill in Clause A4.1.5.9 of Chapter 4) is used. The
compacted material shall comply with the acceptance requirements indicated in Clause A2.1.8.2b).
(iii) Compacted layer thickness
Where the minimum specified degree of compaction cannot be achieved using pedestrian type (walk-behind) rollers or other hand
operated compactors (tampers) the thickness of the layer compacted shall be reduced to achieve the required densities.
b) Compaction and moisture content tolerances
The compaction and moisture content tolerances for backfill shall comply with the requirements of Clause 5.2.2.2 of SANS 2001-DP1.
c) DCP compaction control
DCP compaction acceptance quality control shall only be used for trenches in the unpaved verge of a road reserve.
Where compaction control testing for backfill and trench bottoms is done using a Dynamic Cone Penetrometer (DCP) the following requirements
shall apply:

1. DCP testing shall be limited to a depth that ensures that ducts, pipes or cables are not damaged by the DCP testing.
2. The DCP testing shall be carried out in accordance with the requirements of TMH6-ST6.
3. The following acceptance quality controls shall apply:
• A penetration rate of 25 mm per blow or less shall be achieved over the full depth range or;
• Results with an average penetration rate between 25 mm per blow and 50 mm per blow shall be compared with the results obtained
in the adjacent in situ undisturbed material. The penetration rates achieved in the trench shall be equivalent or better (lower rate)
than the results from the adjacent in situ undisturbed material.
• Should the adjacent in situ undisturbed material test below 25 mm per blow then a maximum of 25 mm per blow shall apply to the
trench backfill.
4. One full depth range DCP test shall be carried out for each 25 m3 of compacted backfill. The minimum sample size per lot or days work
shall be four full depth range DCP tests. A lot will be accepted or rejected as follows:
Table A2.1.8-1: DCP Acceptance requirements
Minimum Number of
Number of Tests
Passing Tests Required
per Lot
for Acceptance of a Lot
4 3
6 5
8 6
10 8
12 10
14 11
16 12
20 16
˃20 80 %
The above DCP acceptance criteria may not be used in the following situations:
• In dolomitic areas where the criteria will be as specified in the Contract Documentation.
• At fills, embankments or cut slopes where the criteria will be provided in the Contract Documentation or as confirmed by the Engineer
if DCP control is permitted.
• In marshy conditions where the in situ soil has a DCP penetration rate above 50 mm per blow and where backfilling material type and
density shall be as specified in the Contract Documentation or as confirmed by the Engineer.
A2.1.8.3 Materials testing and quality control

a) Test methods
The relevant test methods related to the material specifications and control thereof are listed in Clauses A20.1.3.2, A20.1.3.4 and A20.1.3.5 of
Chapter 20, with special tests listed in Clause A20.1.6 of Chapter 20. Any ambiguity concerning the relevance of the test methods and the need
for additional test methods must be brought, in writing, to the attention of the Engineer for a ruling.
b) Acceptance control
The quality control for purposes of acceptance shall be as specified in Table A2.1.8-2.
Table A2.1.8-2: Acceptance control
Property Test Method Lot Size Per Test Number of Tests

Passing the
Requirements
Plastic Index SANS 3001-GR10 100 m3 All
California Bearing Ratio SANS 3001-GR41 400 m3 All
Unconfined SANS 3001-GR53 50 m3 All

Compressive Strength *1
SANS 3001-GR30 for 400 m3 or when material

MDD changes
Relative Density
(% of MDD) SANS 3001-GR35 50 m3 or a minimum of 3
tests per day All
(sand replacement)
or
SANS 3001-NG5
(Nuclear)
*1 Only when instructed by the Engineer.
The statistical principles in Chapter 20 are not applicable to this Clause.

B2.1 GENERAL REQUIREMENTS AND TRENCHING FOR SERVICES
CONTENTS
B2.1.1 SCOPE
B2.1.2 DEFINITIONS
B2.1.3 GENERAL
B2.1.5 MATERIALS
B2.1.8 WORKMANSHIP
B2.1.1 SCOPE
Part B covers the scope for labour enhanced construction associated with the installation of services in a road reserve. Traditionally the installation
of services offers a relative high labour component especially if trenching is done by hand.
Typical activities which can be performed using labour enhanced techniques are clearing and grubbing, removal of surfacing and paving materials
on the trench line, excavation, digging of pilot holes, preparing the bottom of the trench, duct or pipe installation, preparation of backfilling material
and trench backfilling.
Labour enhanced construction methods shall only be used where specified in the Contract Documentation or as ordered by the Engineer.
B2.1.2 DEFINITIONS
Definitions as provided in A2.1.2 shall also apply.
B2.1.3 GENERAL
Any activity specified in Part A where hand work is given as an alternative, shall be executed in such a way as to maximise labour.

B2.1.5 MATERIALS


B2.1.7.1 Classes of excavation
Where excavation is done using labour enhanced construction methods, the Engineer shall classify excavated materials as either soft or
intermediate for payment purposes in terms of Table B2.1.7-1 or, if the Contractor does not agree with the classification, in terms of Table B2.1.7-
2. The decision of the Engineer regarding the classification of the excavated materials shall then be final and binding, subject to the provisions of
the conditions of contract.
No hard material shall be measured under labour enhanced construction methods.
Table B2.1.7-1: Classification of Excavated Materials
Materials
Description
Classification
Material which can be excavated by means of a suitable shovel with or without the use of a pick or other
Soft
hand-swung tool.
Material which is difficult to excavate by hand even with the aid of a crowbar and requires the assistance of
Intermediate
pneumatic tools for economic removal.

Table B2.1.7-2: Classification of Materials in Terms of Consistency and Shear Strength
Consistency Number of DCP Blows to Penetrate 100 mm *1

Materials
Classification
Granular Soil Cohesive Soil Granular Soil Cohesive Soil *2
Soft Very loose to dense Very soft to stiff < 15 <8
Intermediate Very dense Very stiff >15 >8

1
* Only applicable to materials comprising not more than 10 % gravel of size less than 10 mm and materials containing no cobbles or
isolated small boulders.
*2 Classification depends on the moisture content of the cohesive material.
B2.1.8 WORKMANSHIP

C2.1 GENERAL REQUIREMENTS AND TRENCHING FOR SERVICES
(i) Preamble
The tendered rate for each pay item shall include full compensation for providing, operating, maintaining and decommissioning upon completion,
of all the construction equipment, labour, tools, incidentals and supervision to carry out the activity or construct the works in the pay item as
specified, unless otherwise stated.
Any prime cost or provisional sums shall be paid in accordance with the provisions of the conditions of contract. The charge or mark-up tendered
or allowed for is a percentage of the amount actually paid under the prime cost or provisional sum. This percentage shall cover all the Contractor’s
The requirements of Section C1.1 of Chapter 1 shall apply.
Where pay item descriptions include any wording in brackets it is an indication that contract specific information is to be inserted in the Pricing
Schedule included in the Contract Documentation.
(ii) Notes on measurement and pay items
1. Unless otherwise ordered or stated in the Contract Documentation, trench depths will be measured from the surface of the ground along the
centre-line of the trench to the bottom of the specified bedding layer (as applicable). Where no bedding is required it shall be measured to
the underside of the duct or pipe.
2. The ground surface will be that existing after any bulk earthworks have been carried out, i.e. the excavated surface or embankment surface,
unless a different sequence of execution has been ordered.
3. Excavations will be measured as if taken out with vertical sides, regardless of whether they have been taken out with sloping sides.
4. The length used for trench computations will be the total through-length of a pipe or duct etc. from end to end and no deduction will be made
for manholes or access chambers etc.
5. Wherever volumetric measurement is required, the volume will be computed from the depth determined as indicated in 1. and 2. above and
using the authorised width (W) determined in accordance with the specification.
6. Where shoring is specified or ordered, the length of shoring measured for payment will be the length of the centre-line of the trench.
(iii) Items that will not be measured separately
The following activities, whether required to complete the specified work or not, will not be measured and paid for separately and the Contractor
shall include the cost thereof in other pay items as the Contractor deems appropriate:
1. No separate payment will be made for backfilling excess excavations, disposing of surplus material etc. or any other contingent work, unless
the work is specifically specified or ordered.
2. No separate payment will be made for setting out the works.
3. No separate payment will be made for the protection or repair as required of any existing or new road furniture, structures, buildings,
infrastructure or services damaged by the Contractor’s activities and for complying with all the requirements of Clause A2.1.3.4.
4. No additional payment shall be made, nor shall any claim for additional payment be considered, for any specified work in confined or restricted
areas. Any additional costs associated with working in confined or restricted areas shall be deemed to be included in the standard applicable
pay items.
5. No separate payment will be made for the loading of any materials.
6. No separate payment will be made for the hauling of any materials where the material is moved over a distance of less than and up to 1,0 km.
7. No separate payment will be made for transporting materials from commercial sources irrespective of the haul distance.
8. No separate payment will be made for the removal of any surplus material imported to complete the works.
(iv) Items to be measured and paid for using items specified elsewhere in the specifications
For activities in Table C2.1-1 pay items specified in other Chapters or Sections of the specifications, where they relate to work under this section,
will be listed in the Pricing Schedule.
A2.1.3.3c) & Section C1.5 of Chapter 1 - All

Traffic accommodation
A2.1.3.9b) applicable items
The removal of large trees (girth exceeding 1,0 m) and the A2.1.7.1e) Section C1.6 of Chapter 1 - All
removal and conservation of topsoil applicable items
C2.1.6, C2.1.9, C2.1.11, C2.1.17 & Section C1.7 of Chapter 1 - All
Hauling materials applicable items
C2.1.23
Borrow and spoil areas: Section C4.1 of Chapter 4 - All
• Opening and closing down applicable items
C2.1.11, C2.1.17 & C2.1.23
• Excess overburden
• Rehabilitation
Section C4.1 of Chapter 4 - All
Temporary stockpiling of excavated material A 2.1.7.1f) applicable items
Section C6.2 of Chapter 6 – All

Segmented block and in situ concrete paving A 2.1.7.2b) applicable items

Road markings A 2.1.7.2c) applicable items 7
A2.1.7.1e), A2.1.7.2d), C2.1.6 & Section C11.8 of Chapter 11 - All
Placing of top soil and establishment of vegetation applicable items
C2.1.9
Trenchless methods A2.1.7.5 applicable items
Chapter 13 - All applicable items
Special concrete and steel structures A 2.1.7.3
(v) Items specifically for this Section of the specification
C2.1.1 Location, identification, protection and relocation of existing services
C2.1.1.1 Contractor’s obligations lump sum
C2.1.1.2 Permanent services relocation or protection work by others prime cost (PC) sum
C2.1.1.3 Handling costs and profit in respect of item C2.1.1.2 above percentage (%)
C2.1.1.4 Permanent services relocation or protection work by the Contractor provisional sum
The lump sum tendered under item C2.1.1.1 shall be in full compensation for all the Contractor’s obligations under Clauses A2.1.3.2, A2.1.3.3a),
A2.1.3.3b) and A2.1.3.5 for the location, identification and protection of existing services and for safety and safeguarding and the programming
for services.
The prime-cost item C2.1.1.2 shall be paid for work done by others in accordance with the provisions of the conditions of contract for work ordered
or agreed by the Engineer. The tendered percentage for item C2.1.1.3 is a percentage of the amount actually spent under the prime-cost item,
which shall include full compensation for the handling, supervision and liability costs of the Contractor and the profit in connection with providing
the specified service.
The provisional sum under item C2.1.1.4 shall be paid for work done by the Contractor accordance with the provisions of the conditions of contract
for work ordered or agreed by the Engineer.
C2.1.2 Existing services location, detection and verification
C2.1.2.1 Using specialist detection services (ground penetrating radar, radio detection etc.) prime cost (PC) sum
C2.1.2.3 Survey to verify existing service positions prime cost (PC) sum
C2.1.2.5 Using hand excavation to locate, expose and verify services cubic metre (m3)
The prime-cost item C2.1.2.1 will cover the costs of any specialist detection services used to locate, detect and verify existing services. The use
of any specialist detection service providers shall be approved by the Engineer prior to their appointment.
The prime-cost item C2.1.2.3 will cover the costs of any survey services used to determine, fix and record the positions of an existing service after
it has been located. The use of any survey service providers shall be approved by the Engineer prior to their appointment.
The prime-cost items C2.1.2.1 and C2.1.2.3 shall be paid for in accordance with the provisions of the conditions of contract. The tendered
percentage for items C2.1.2.2 and C2.1.2.4 shall be a percentage of the amount actually spent under the prime-cost item, which shall include full
compensation for the handling, supervision and liability costs of the Contractor and the profit in connection with providing the specified service.
The unit of measurement for item C2.1.2.5 shall be a cubic metre of material excavated within the lengths and widths authorised by the Engineer
and the depth required to expose the service. Excavation in excess of the authorised dimensions shall not be measured for payment.
The tendered rate for item C2.1.2.5 shall include full compensation for all excavation, backfilling, compacting to 90 % of MDD, disposing of any
surplus excavated material, keeping the excavations safe, dealing with any surface or subsurface water, taking special care to ensure that services
are not damaged in any way and any other operation necessary for completing the work. The tendered rate shall also include the transporting of
surplus excavated material for a haul distance of 1,0 km. Any damage to a service caused by the Contractor’s negligence shall be repaired at his
own cost, to the satisfaction of the owner of the service and the Engineer. No distinction will be made between the classes of material, neither
will distinction be made between the various types of services to be exposed or the depths to which excavations are taken.

C2.1.3 Obtaining construction or work permits lump sum

The tendered lump sum shall be in full compensation for all the work required to obtain and arrange for all the necessary construction or work
permits in accordance with Clause A2.1.3.8 and Clause A1.2.3.22b) of Chapter 1. The tendered lump sum shall exclude any deposits or the costs
of any guarantees required by service owners or other authorities which will be payable under item C2.1.4.
C2.1.4 Provision of guarantees or deposits for services
C2.1.4.1 Providing guarantees and deposits prime cost (PC) sum
The prime-cost item C2.1.4.1 shall be for any deposits or for the costs of any guarantees required by any service owners or other authorities
before any work is permitted in the vicinity of their services etc. and the item shall be paid for in accordance with the provisions of the conditions
of contract. Payment under this item will be made when deposits or guarantee payments have been made by the Contractor and acceptable proof
of such deposits or payments have been provided to the Engineer. No interest will be paid to the Contractor on these amounts. Where any
deposits or guarantee amounts are returned to the Contractor payment under this item will be reversed accordingly. The tendered percentage for
item C2.1.4.2 is a percentage of the amount actually spent under the prime-cost item, which shall include full compensation for the handling,
supervision and liability costs of the Contractor and the profit in connection with providing the specified service. Payment under item C2.1.4.2 will
not be reversed when any deposits or guarantee payments are returned.
C2.1.5 Provision of record drawings and applicable data lump sum

The tendered lump sum shall be in full compensation for providing the complete record drawings and any other applicable data in accordance
with the requirements of Clause A2.1.3.6 including the costs for surveying the final positions of new or relocated services. The lump sum will be
paid after all the required drawings and data have been delivered to, and accepted by, the Engineer.
C2.1.6 Trench excavation (in soft material)
C2.1.6.1 Trenches up to 1,0 m wide
(a) Up to 1,0 m deep cubic metre (m3)
(b) Over 1,0 m and up to 2,0 m deep cubic metre (m3)
(c) Over 2,0 m deep etc. to be inserted, increased by additional 1,0 m depths as required cubic metre (m3)
C2.1.6.2 Trenches over 1,0 m and up to 2,0 m wide
(c) Over 2,0 m deep etc., increased by additional 1,0 m depths as required cubic metre (m3)
Trenches over 2,0 m wide and up to 3,0 m etc., increased by additional 1,0 m widths as
C2.1.6.3
required
(c) Over 2,0 m deep etc., increased by additional 1,0 m depths as required cubic metre (m3)
The unit of measurement shall be the cubic metre of material excavated as if in soft material, classified according to the various width and depth
ranges listed. The depth classification shall be in accordance with the total depth of the trench for each length of trench excavated and not in
accordance with the depth range in which material is situated before excavation i.e. for a section of trench which is up to 1,0 m wide and 1,3 m
deep the total volume of excavation will be measured under pay item C2.1.6.1(b). For measurement purposes the width of a trench shall be
determined from the authorised dimensions and the depth of excavation shall be measured to the underside of the bedding, except where no
bedding is required, in which case it shall be measured to the underside of the duct or pipe.
The tendered rates shall include full compensation for setting out, clearing and grubbing the trench areas except for trees with a girth larger than
1,0 m, the temporary removal of improvements from the line of the trench, the removal and stacking of any surfacing and paving material as
applicable, for excavating the trench, preparing the bottom of the trench, separating topsoil, material unsuitable for backfill and selected backfill
material, for safeguarding and keeping the excavations safe, which includes the provision, installation and later removal of temporary timbering,
shoring and strutting, dealing with any surface or subsurface water and for the temporary stockpiling of material unless otherwise specified in the
Contract Documentation. The tendered rates shall include full compensation for trimming trench excavations by hand or by using mechanical
equipment and for hauling material within a haul limit of 1,0 km. Excavations in bolsters i.e. tunnels less than 3,0 m in length will be measured
and paid for as trench excavations. Where saw-cutting of the excavation edge is required and/or ordered prior to excavation it will be measured
and paid under the relevant items.

C2.1.7 Extra over items C2.1.6, C2.1.8 and C2.1.16 for excavating in:
C2.1.7.1 Hard material irrespective of depth cubic metre (m3)
C2.1.7.2 Stabilised material irrespective of depth cubic metre (m3)

The unit of measurement shall be the cubic metre of material excavated (irrespective of depth) and classified as hard material or as stabilised
material, in accordance with the classification in Clauses A2.1.7.1i)(i) and A2.1.7.1i)(ii).
The tendered rates shall be paid over and above the rate tendered for excavation in respect of items C2.1.6, C2.1.8 and C2.1.16 and shall include
full compensation for the additional cost of excavating in material other than soft material. The tendered rates shall include full compensation for
any overbreak as well as the additional backfilling required, reinstating the trench bottom, and for any other incidentals resulting from overbreak.
C2.1.8 Excavations outside the normal trench profile cubic metre (m3)
The unit of measurement shall be the cubic metre of material excavated, if necessary, using excavating equipment or by hand outside the normal
trench profile as specified in Clause A2.1.7.1k).
The tendered rate shall include full compensation for excavating outside the normal trench profile, trimming the excavations, preparing the bottom
of the excavation, separating any material unsuitable for backfill from selected backfill material, keeping excavations safe, dealing with any surface
or subsurface water and for the temporary stockpiling of material unless otherwise specified in the Contract Documentation.
C2.1.9 Trench excavation using labour enhanced construction methods
C2.1.9.1 Trenches up to 1,0 m wide (in soft material)
C2.1.9.2 Trenches over 1,0 m and up to 2,0 m wide (in soft material)
C2.1.9.3 Trenches up to 1,0 m wide (in intermediate material)
C2.1.9.4 Trenches over 1,0 m and up to 2,0 m wide (in intermediate material)

The unit of measurement shall be the cubic metre of soft or intermediate material, classified in accordance with Clause B2.1.7.1, excavated using
labour enhanced construction methods and hand tools (picks and/or hand shoves) as instructed or authorised in writing by the Engineer in
accordance with the provisions of Clauses A2.1.7.1j). Excavation will be classified according to the various depths and widths listed. The depth
classification shall be in accordance with the actual depth of the trench for each length of trench excavated and not in accordance with the depth
range in which material is situated before excavation i.e. for a section of trench which is up to 1,0 m wide and 1,3 m deep the total volume of
excavation will be measured under item C2.1.9.1(b). For measurement purposes the width of a trench shall be determined from the authorised
dimensions and not from the width range listed and the depth of excavation shall be measured to the underside of the bedding, except where no
bedding is required, in which case it shall be measured to the underside of the duct or pipe.
The tendered rates shall include full compensation for setting out, clearing and grubbing the trench areas except for trees with a girth larger than
1,0 m, the temporary removal of improvements from the line of the trench, the removal and stacking of any surfacing and paving material as
applicable, for excavating the trench, preparing the bottom of the trench, separating topsoil, material unsuitable for backfill and selected backfill
material, for safeguarding and keeping the excavations safe, which includes the provision, installation and later removal of temporary timbering,
shoring and strutting, dealing with any surface or subsurface water and for the temporary stockpiling of material unless otherwise specified in the
Contract Documentation. Excavations in bolsters i.e. tunnels less than 3,0 m in length will be measured and paid for as trench excavations.
Where saw-cutting of the excavation edge is required and/or ordered prior to excavation it will be measured and paid under the relevant pay items.
The tendered rates shall include full compensation for loading and transport by wheelbarrow if the material is disposed of or utilised within a
distance of 50 m of the point of excavation, or alternatively loading by hand onto transport vehicles for such disposal or utilisation elsewhere,
within a haul limit of 1,0 km.
Item C2.1.9 shall be applicable where excavation by hand is required in terms of Clauses A2.1.3.9a) and A2.1.7.1j).

C2.1.10 Excavation in tunnels exceeding 3,0 m in length in:
C2.1.10.1 Soft material cubic metre (m3)
C2.1.10.2 Hard material cubic metre (m3)

The unit of measurement shall be the cubic metre of material excavated in tunnels exceeding 3,0 m in length in accordance with the authorised
dimensions.
The tendered rates shall be in full compensation for excavating by hand or machine in tunnels through soft material or hard material, separating
any material unsuitable for backfill from selected backfill material, keeping excavations safe, dealing with any surface or subsurface water, for
supporting the roof if necessary, for compacting the floor of the tunnel if necessary, and for temporary stockpiling of material unless otherwise
specified in the Contract Documentation.
This item shall apply only to tunnels exceeding 3,0 m and up to 10,0 m in length. Tunnels up to 3,0 m long i.e. bolsters, shall be paid as trench
excavation.
C2.1.11 Backfilling of trenches

C2.1.11.1 Backfill compacted to 93 % (100 % for sand) of MDD (areas subject to traffic loads) using
material:
(a) From the excavated trench material cubic metre (m3)
(b) From other excavations on site cubic metre (m3)
(c) From approved borrow areas cubic metre (m3)
(d) From sources provided by the Contractor cubic metre (m3)
(e) From commercial sources (state material type) cubic metre (m3)
C2.1.11.2 Backfill compacted to 90 % (100 % for sand) of MDD or complying with the DCP
requirements of Clause A2.1.8.2c) (areas not subject to traffic loads) using material:
(e) From commercial sources (state material type) cubic metre (m3)
The unit of measurement for items C2.1.11.1 and C2.1.11.2 shall be the cubic metre of backfill material in place after compaction calculated from
the specified or authorised trench excavation dimensions and placed above the fill blanket or bedding, as applicable. Backfill required for trenches
excavated outside the specified or authorised dimensions will not be measured unless such excavation is authorised and measured under item
C2.1.8.
The tendered rates shall be in full compensation for the backfilling of trenches including placing the material in the trench, watering and compacting
the backfill to the specified minimum density using relative density or DCP compaction control as applicable.
The tendered rates for items C2.1.11.1(b), C2.1.11.1(c), C2.1.11.2(b) and C2.1.11.2(c) shall include full compensation for the additional cost of
excavation in all materials, for loading the material from an excavation on site or from a borrow pit, for hauling the material within a haul limit of
1,0 km and for unloading the material for placement. The tendered rate for items C2.1.11.1(c) and C2.1.11.2(c) shall include full compensation
for all operations at borrow pits not subject to any specified separate pay item.
The tendered rates for items C2.1.11.1(d), 2.1.11.1(e), C2.1.11.2(d) and C2.1.11.2(e) shall include full compensation for the payment of any
royalties or charges for procuring and furnishing the material from sources provided by the Contractor or from commercial sources as well as for
transporting the material over an unlimited haul distance.

Backfilling additional excavations in trench floors due to poor founding conditions
C2.1.12
using:
C2.1.12.1 Geotextile (state grade or class) square metre (m2)
C2.1.12.2 Concrete aggregate (37,5 mm aggregate size) cubic metre (m3)
C2.1.12.3 Concrete (state class) cubic metre (m3)

The unit of measurement for item C2.1.12.1 shall be the square metre of geotextile placed on the trench bottom, as ordered by the Engineer. The
unit of measurement for items C2.1.12.2 and C2.1.12.3 shall be the cubic metre of concrete aggregate or concrete placed on the trench bottom,
as ordered by the Engineer.
The tendered rates for items C2.1.12.1, C2.1.12.2 and C2.1.12.3 shall include full compensation for procuring, furnishing and placing the
geotextile, aggregate or concrete on the trench bottom including any mixing or compaction required.

Where the Engineer orders that selected backfill material or soil cement be used to backfill the trench bottom payment shall be made under items
C2.1.11 and C2.1.13.
C2.1.13 Extra over item C2.1.11 for backfilling with soil cement or stabilised material
C2.1.13.1 Backfilling trenches using soil cement using (state type of material i.e. G5, G7 or G8) cubic metre (m3)
material
C2.1.13.2 Backfilling trenches using stabilised (state type of material i.e. G5, G7 or G8) material cubic metre (m3)
compacted to 93 % of MDD
C2.1.13.3 Backfilling around poles using stabilised (state type of material i.e. G5, G7 or G8) material cubic metre (m3)
compacted to 95 % of MDD
C2.1.13.4 Cement (state class of cement) kilogram (kg)

The unit of measurement for item C2.1.13.1 shall be the cubic metre of soil cement material in place calculated from the specified or authorised
trench excavation dimensions less the volume occupied by a duct, pipe, casing, pole or footing.
The unit of measurement for items C2.1.13.2 and C2.1.13.3 shall be the cubic metre of cement stabilised material in place after compaction
calculated from the specified or authorised trench or hole excavation dimensions less the volume occupied by a duct, pipe, casing, pole or footing.
The unit of measurement for item C2.1.13.4 for the cement added to achieve the cement content, as instructed by the Engineer, in soil cement
and stabilised material shall be the kilogram.
The tendered rate for item C2.1.13.1 shall include full compensation for the additional costs of procuring and furnishing the type of material
specified and for mixing in the cement and placing and compacting the soil cement material as specified in Clause A2.1.7.1s)(i). Payment for the
backfill material mixed with the cement will be made under item C2.1.11.
The tendered rates for items C2.1.13.2 and C2.1.13.3 shall include full compensation for procuring and furnishing the type of material specified
and for mixing in the cement and placing and compacting the stabilised material. Payment for the backfill material mixed with the cement will be
made under item C2.1.11.
The tendered rate for item C2.1.13.4 shall include full compensation for procuring and furnishing the cement added to achieve the final cement
content, as instructed by the Engineer, in soil cement or stabilised material.
C2.1.14 Extra over items C2.1.11, C2.1.12 and C2.1.13 for additional compaction of backfill
C2.1.14.1 Compaction increased from 90 % of MDD to 93 % of MDD cubic metre (m3)

The unit of measurement shall be the cubic metre of material subjected to additional compaction, as ordered by the Engineer.
The tendered rates shall be paid as extra over the rates for items C2.1.11, C2.11.12 and C2.1.13 and shall include full compensation for the
additional cost resulting from a higher compaction requirement for backfill ordered by the Engineer. Payment under this item will only be made
where the Engineer has ordered, in writing, that a specified part or parts of the backfill be compacted to a higher minimum density than the
standard specified under items C2.1.11, C2.1.12 and C2.1.13.
C2.1.15 Stone packing
C2.1.15.1 In bolsters cubic metre (m3)
C2.1.15.2 In tunnels cubic metre (m3)

The unit of measurement shall be the cubic metre of stone packing constructed as specified in Clause A2.1.7.1o), determined from the authorised
dimensions. The tendered rates shall include full compensation for procuring, furnishing and placing the stones and sand required, including all
haul, and for hand packing the stones and filling the voids with sand as specified.
Subsurface drains in trench bottoms (Contract Documentation reference or drawing

C2.1.16 metre (m)
number indicated)
The unit of measurement shall be the metre of subsoil drain constructed complete as specified or shown on the drawings.
The tendered rate shall include full compensation for constructing the subsoil drain complete, including excavation by hand in soft material, the
supply and installation of geotextiles and pipes and the supply and placing of any drainage aggregate. The rate shall be subject to an extra over-
payment under item C2.1.7 and shall also be subject to additional payment under item C2.1.17 for the removal disposal of any surplus or unsuitable
excavated material to spoil sites provided either by the Employer or the Contractor.

C2.1.17 Removal and disposal of spoil material from trench excavations:

C2.1.17.1 To spoil sites provided by the Employer as indicated in the Contract Documentation or as cubic metre (m3)
instructed by the Engineer
C2.1.17.2 To spoil sites or dumping areas provided by the Contractor cubic metre (m3)
The unit of measurement shall be the cubic metre of material surplus to requirements or unsuitable for further use as backfill etc., calculated from
the specified or authorised trench excavation dimensions, and which has to be spoiled as ordered by the Engineer.
The tendered rate for items C2.1.17.1 and C2.1.7.2 shall include full compensation for loading, off-loading and disposing of spoil material from
trench excavations as specified including shaping and levelling off of any piles of spoil material. The tendered rate for item C2.1.17.1 shall also
include full compensation for hauling the material up to the haul limit of 1,0 km. The tendered rate for item C2.1.7.2 shall also include full
compensation for hauling the material over an unlimited distance, for providing the spoil site or dump area and the rate shall include any relevant
payments to the affected land or dump site owners.
The tendered rates shall also include the provision of haul roads and the clearing up and finishing of haul roads, spoil sites and dumping areas on
completion of the work. Where spoil is paid under pay item C2.1.17.1 the relevant pay items for finishing-off and rehabilitating borrow areas will
apply.
C2.1.18 Timbering, strutting and shoring

C2.1.18.1 Timbering, strutting and shoring left in excavations square metre (m2)
C2.1.18.2 Timbering, strutting and shoring opposite a structure or service (state reference in Contract metre (m)
Documentation or indicate drawing number etc.)
Item C2.1.18.1 will only be applicable, as indicated in Clause A2.1.7.1l)(ii), where the Engineer instructs that timbering, strutting and shoring be
permanently left in place in excavations. The unit of measurement for item C2.1.18.1 shall be the square metre of tunnel wall or roof or trench
wall against which timbering and shoring is required to be left in position permanently on the Engineer's instructions. Each side of the trench or
tunnel shall be measured.
Item C2.1.18.2 will only be applicable, as indicated in Clause A2.1.7.1l)(ii), where separate payment for timbering and shoring is indicated and
described in the Contract Documentation. The unit of measurement for item C2.1.18.2 shall be the metre of trench shored opposite a structure
or service as agreed by the Engineer. The length measured for payment will be that of the centre-line of the trench regardless of whether supports
are placed on one or on both sides of the trench.
The tendered rate for item C2.1.18.1 shall include full compensation for leaving the timbering and shoring permanently in position, for ensuring
that the timbering and shoring will not be disturbed during backfilling, and that the backfilling is compacted fully around the shoring.
The tendered rate for item C2.1.18.2 shall include full compensation for the cost, for both sides of the trench if necessary, of the supply, placing,
maintenance and removal of timbering and other support measures together with any cost that results from the inconvenience of working in the
supported trench and the cost of any risks inherent in the operation.
C2.1.19 Dealing with water during services work
C2.1.19.1 Dealing with surface water lump sum
C2.1.19.2 Dealing with subsurface water lump sum

The tendered sums for items C2.1.19.1 and C2.1.19.2 shall cover the cost for the provision, operation, maintaining and removal of all construction
equipment and materials required to deal with any water anywhere on the site as required in terms of Clause A2.1.7.1r)(i).
The lump sum shall cover the cost of providing the necessary construction equipment or materials, or both, fully erected and operative on the site,
and shall cover the cost of operating and maintaining pumps, well points, sheeting, close timbering, and other equipment, as applicable, for 24
hours a day, 7 days a week, throughout the period during which the facilities are required, and shall cover the cost of removing such goods and
restoring the site to its original condition on completion of that part of the contract for which the temporary works were erected.
Two equal payments will be made under each subitem, the first after the Contractor has commenced with the services work and the second when
all the services work has been completed.

C2.1.20 Specified temporary works to control water inflow (state reference in Contract
Documentation or indicate drawing number etc.)
C2.1.20.1 Provide equipment lump sum
C2.1.20.2 Operate and maintain day
C2.1.20.3 Remove equipment lump sum

Item C2.1.20 will only be applicable, as indicated in Clause A2.1.7.1r)(ii), where separate payment for the control of water inflow is indicated in
the Contract Documentation. The unit of measurement for item C2.1.20.2 shall be the 24 hour day.
The sums tendered for items C2.1.20.1 and C2.1.20.3 shall include full compensation for the provision and removal of equipment and shall cover
the cost of providing the necessary equipment or materials or both, fully erected and operative on the site, and of removing such goods and
restoring the site to its original condition on completion of that part of the contract for which the temporary works were erected.

The rate tendered for item C2.1.20.2 shall include full compensation for operation and maintenance and shall cover the cost of operating and
maintaining the pumps, well points, sheeting, close timbering and other equipment, as applicable, for 24 hours per day, 7 days a week throughout
the period during which, as agreed by the Engineer, the facilities are required.
C2.1.21 Supply and installation of sandbags in trenches
C2.1.21.1 Biodegradable bags (state bag size, material type and description) number of bags (No)
C2.1.21.2 Geofabric bags (state bag size, material type and description) number of bags (No)
The unit of measurement shall be the number of bags filled with soil installed in accordance with the Clause A2.1.7.1n). The tendered rates shall
include full compensation for supplying the bags and suitable material to fill the bags, filling of the bags with soil and placing the bags as required
and shall also include all associated transport costs. The tendered rates shall include full compensation for removing the bags when no longer
required.
C2.1.22 Existing services that intersect or adjoin a trench
C2.1.22.1 Services that intersect a trench (angles between centre-lines in plan 45 o to 90 o)
(a) State type and size of each intersecting service number (No)
(b) State type and size of each intersecting service number (No)
(c) State type and size of each intersecting service etc. number (No)
Services that adjoin a trench (parallel to or at an angle between
C2.1.22.2
centre-lines in plan of less than 45 o)
(a) State type and size of each adjoining service metre (m)
(b) State type and size of each adjoining service metre (m)
(c) State type and size of each adjoining service etc. metre (m)
The unit of measurement for item C2.1.22.1 shall be the number of underground services intersected by the trench excavated. Existing water
pipes, sewers, stormwater pipes, concrete-lined channels and drains, box culverts, electric or other telecommunication cables, ducts, kerbs,
channels, erf connections and various sizes of pipes and services that intersect a trench of specified width and require various degrees of care,
whether or not their presence was known before they were uncovered, will be measured separately. The unit refers to one service, but services
that are so grouped that they can be contained within a horizontal dimension of 300 mm measured at right angles to the axis of the services will
be measured as one unit.
The unit of measurement for item C2.1.22.2 shall be the metre of trench excavated where there are adjoining services. In a case where a trench
of specified width:
• Runs parallel to or at an angle (in plan) of less than 45 o to an existing service, and
• Is such that the nearer side of the bottom of the trench lies at least partly between a vertical plane and a plane that lies at an angle of
45 o below the horizontal, both planes passing through the axis of the service,
the length of service within the minimum base width of the trench, determined in accordance with Clause A2.1.7.1h), will be measured for payment
under this item and the remaining length, the side of the trench which, as agreed by the Engineer, is rendered liable to collapse because of the
existence of such service, will be measured for shoring.
The tendered rates for items C2.1.22.1 and C2.1.22.2 shall include full compensation for the additional cost of:
• Care in excavation necessitated by the presence of services adjacent to, in or across a trench;
• Protecting and maintaining such services in operation by means of temporary supports or shoring, as necessary;
• Delays and disruption of the progress of the work due to the existence of the services; and
• Repairs necessitated by damage caused by the Contractor.
Item C2.1.22 shall not be applicable where any services are to be removed and where payment will therefore be made under item C1.2.25.
C2.1.23 Reinstatement of trenches in existing surfaced roads using:

C2.1.23.1 Selected material (state material type and source e.g. G7 or G8, commercial/borrow pits/etc. cubic metre (m3)
and layer thickness) compacted to (state minimum compaction) % of MDD
C2.1.23.2 Subbase material (state material type and source e.g. G5 or G6, commercial/borrow pit etc. cubic metre (m3)
and layer thickness) compacted to (state minimum compaction) % of MDD
C2.1.23.3 Stabilised subbase material (state material type and source e.g. C3 or C4, cubic metre (m3)
commercial/borrow pit etc. and layer thickness) using (state percentage and type of
stabilising agent) compacted to (state minimum compaction) % of MDD
C2.1.23.4 Base material (state material type and source e.g. G1 or G2, commercial/quarry etc. and cubic metre (m3)
layer thickness) compacted to (state minimum compaction either 102 % for G2 or 104 % for
G1) % of MDD

C2.1.23.5 Prime coat (state type of material and application rate) square metre (m2)
C2.1.23.6 Tack coat (state type of material and application rate) square metre (m2)
C2.1.23.7 Asphalt material (state asphalt type e.g. continuously graded, binder type, layer thickness ton (t)
and minimum density)
C2.1.23.8 Surface treatments (state surfacing type, binder type and application rate, aggregate size square metre (m2)
and application rate etc.)
The unit of measurement for items C2.1.23.1, C2.1.23.2, C2.1.23.3 and C2.1.23.4 shall be the cubic metre of compacted pavement layer
constructed during the reinstatement of existing surfaced roads. The unit of measurement for items C2.1.23.5 and C2.1.23.6 shall be the square
metre of prime or tack coat placed during the reinstatement of existing surfaced roads. The unit of measurement for item C2.1.23.7 shall be the
ton of compacted asphalt and the unit of measurement for item C2.1.23.8 shall be the square metre of surface treatment both placed during the
reinstatement of existing surfaced roads. Items C2.1.23.1 to C2.1.23.8 will be measured in accordance with the authorised dimensions for the
reinstatement area required. Any reinstatement required beyond the agreed or instructed dimensions owing to damage caused by the Contractor
will not be measured for payment.
The tendered rates shall include full compensation for procuring, furnishing, placing, compacting and finishing all the materials including stabilising
the layers as may be required and including full compensation for providing all labour and construction equipment, preparing the edges of the
existing surfacing and protecting and maintaining the completed reinstatement as specified. The tendered rate shall also include full compensation
for any temporary backfilling with excavated material and for compacting, maintaining and later removing the temporary material as specified in
Clause A2.1.7.2b).
Where the materials are supplied from sources provided by the Contractor or from commercial sources the tendered rates shall include full
compensation for the payment of any royalties or charges for procuring the material from sources provided by the Contractor or from commercial
sources as well as for transporting the material over an unlimited haul distance. Where the materials are sourced from borrow pits or quarries
provided by the Employer or other sources on site the tendered rates shall include full compensation for hauling the materials within the haul limit
of 1,0 km, for unloading the material for placement and for all operations at borrow pits or quarries not subject to any specified separate pay item.
The backfill of the trench up to the bottom of the layers measured under item C2.1.23 will be paid for under items C2.1.11, C2.1.12, C2.1.13 and
C2.1.14 as applicable.
C2.1.24 Saw-cutting before excavation
C2.1.24.1 Saw-cutting asphalt to an average depth:
(a) Not exceeding 50 mm square metre (m2)
(b) Exceeding 50 mm but not exceeding 100 mm square metre (m2)
(c) Exceeding 100 mm but not exceeding 150 mm square metre (m2)
C2.1.24.2 Saw-cutting concrete to an average depth:
C2.1.24.3 Saw-cutting other materials (type of material to be specified) to an average depth:
The unit of measurement shall be the square metre of cut area, saw-cut before excavation in accordance with Clause A2.1.7.1d), calculated in
accordance with the authorised length of cut and the average depth measured after excavation of the material.
The tendered rates for item C2.1.24 shall include full compensation for all construction equipment, tools, labour, supervision, materials, transport
and for all incidentals for cutting the asphalt, concrete or other materials complete as specified and also for work in restricted areas.

C2.1.25 Removal of existing services:
C2.1.25.1 State type and size of each service (duct, pipe or cable) removed metre (m)
C2.1.25.2 State type and size of each service (duct, pipe or cable) removed metre (m)
C2.1.25.3 Etc., insert additional items as required metre (m)

The unit of measurement shall be the metre of existing service of each type removed.
The tendered rates for item C2.1.25 shall include full compensation for removing an existing service including dismantling the service, uplifting,
loading, off-loading and storing the recovered material on site as agreed with the Engineer. The tendered rates shall include full compensation
for removing all joints, specials, valves etc associated with the service removed.
The demolition of any structures and the excavation and backfill that may be associated with the removal of a service will be measured and paid
separately.
C2.1.26 Disposal of existing service materials:
C2.1.26.1 State type and size of each service (duct, pipe or cable) disposed of metre (m)
C2.1.26.2 State type and size of each service (duct, pipe or cable) disposed of metre (m)

The unit of measurement shall be the metre of existing service material disposed of in accordance with Clause A2.1.7.6.
The tendered rate for item C2.1.26 shall include full compensation for disposing of existing service material including loading, removal from site,
transporting the material over an unlimited haul distance and off-loading the material at the disposal site. The tendered rates shall include full
compensation for disposing of all joints, specials, valves etc associated with the service, for any related disposal costs and for providing the
Engineer with the disposal records. The tendered rates may be positive or negative as considered appropriate by the Contractor for each service
type.
The removal of services will be measured and paid separately under item C2.1.25.

C2.1.27 Demolition of existing manholes, access chambers and other service structures
consisting of:
C2.1.27.1 Unreinforced concrete cubic metre (m3)
C2.1.27.2 Reinforced concrete cubic metre (m3)
C2.1.27.3 Masonry cubic metre (m3)

The unit of measurement shall be the cubic metre, measured prior to demolition, of concrete or masonry demolished and disposed of.
The tendered rate shall include full compensation for all labour and construction equipment and for all work necessary for, and incidental to, the
demolition of the structures. The tendered rates shall include full compensation for the disposal of all rubble and material from the demolition at
an approved disposal site including transporting the material over an unlimited haul distance to the disposal site.
For the purposes of this item reinforced concrete shall be taken to mean concrete which contains at least 0,2 % of steel by volume.
Excavation and backfilling will be measured and paid separately.

D2.1 GENERAL REQUIREMENTS AND TRENCHING FOR SERVICES
CONTENTS
D2.1.1 SCOPE
D2.1.2 GENERAL
D2.1.1 SCOPE
D2.1.1.1 Proprietary products and materials
The Contractor shall provide detailed specifications and certificates from independent agencies for all proprietary materials that are proposed for
use. These certificates shall demonstrate conformance with the performance requirements stipulated in these standard specifications or in the
Unless otherwise specified all proprietary products and materials shall be used strictly in accordance with the relevant manufacturer’s or supplier’s
current published instructions or requirements for the specified product.
Agrément certified products shall be used and placed in accordance with their Agrément certification criteria.
D2.1.1.2 Compliance certification for standard specifications

Where products or materials used are required to comply with any specified standard specifications the Contractor shall, if and when so ordered
by the Engineer, furnish the Engineer with all relevant certificates or test results to verify that the products or materials used comply with the
applicable standards.
Where so specified products or materials shall bear the official mark of the appropriate authority. As required specified products or materials
subject to a SANS standard or specification shall carry a SABS mark or a certification mark by any other SANAS accredited certification body for
the applicable SANS specification.
Where required suitable samples of the proposed products or materials shall be delivered to the Engineer’s office on site free of charge.

2.2 DRY SERVICES
CONTENTS
A2.2.1 SCOPE
A2.2.2 DEFINITIONS
A2.2.3 GENERAL
A2.2.5 MATERIALS
A2.2.8 WORKMANSHIP

A2.2 DRY SERVICES

A2.2.1 SCOPE
Section A2.2 of Chapter 2 covers the civil engineering components for the construction work associated with the installation of dry services (ducts
for telecommunications, electricity and street lighting) and ancillary works in road reserves.
All dry services shall be installed at the locations shown and in accordance with the details shown on the drawings, provided in the Contract
Documentation or as directed by the Engineer.

In certain SANS documents referred to in this Section the term “specified in the scope of work” is used. For the purposes of this specification the

SANS 558 Cast iron surface boxes and manhole and inspection covers and frames
SANS 677 Concrete non-pressure pipes
SANS 819 Fibre-cement pipes, couplings and fittings for sewerage, drainage and low-pressure irrigation
SANS 920 Steel bars for concrete reinforcement
SANS 1936-1 Development of dolomite land Part 1: General principles and requirements
SANS 1936-3 Development of dolomite land Part 3: Design and construction of buildings, structures and
infrastructure
SANS 2001-DP3 Cable ducts

SANS 4427-1 Plastic piping systems: Polyethylene (PE) pipes and fittings for water supply
SANS 10140-3 Identification colour markings Part 3: Contents of pipelines
SANS 50124 Gully tops and manhole tops for vehicular and pedestrian
areas
SANS 61386-1 Conduit systems for cable management Part 1: General requirements
SANS 61386-24 Conduit systems for cable management Part 24: Particular requirements – Conduit systems
buried underground
ASTM F 2160 Standard Specification for Solid Wall High Density Polyethylene (HDPE) Conduit Based on
Controlled Outside Diameter (OD)

ASTM F 2176 Standard Specification for Mechanical Couplings Used on Polyethylene Conduit, Duct and
Innerduct
EN 124-1 Gully tops and manhole tops for vehicular and pedestrian areas Part 1: Definitions, classification,
general principles of design, performance requirements and test methods
EN 124-2 Gully tops and manhole tops for vehicular and pedestrian areas Part 2: Gully tops and manhole
tops made of cast iron
tops made of steel or aluminium
tops made of steel reinforced concrete
tops made of composite materials
tops made of polypropylene (PP), polyethylene (PE) or unplasticised poly (vinyl chloride) (U-
PVC)
A2.2.2 DEFINITIONS
Fibre Optic Telecommunication - fibre optic communication is a method of transmitting information from one place to another by sending pulses
of light through an optical fibre. The light forms an electromagnetic carrier wave that is modulated to carry information.
Handhole - a shallow form of manhole giving access to ducts in an underground cable (normally communications) system.
Micro Trenching – a trench (slot), with a width up to but not exceeding 40 mm, providing at least 300 mm cover over the upper most duct in a
duct bank, cut into a road or footway.
Mini Trenching - a trench (slot), with a width greater than 40 mm but not exceeding 100 mm, providing at least 300 mm cover over the upper
most duct in a duct bank, cut into a road or footway.
A2.2.3 GENERAL
The location, identification, protection and relocation of existing services, unknown or unrecorded services shall be managed in accordance with
Clause A2.1.3.2.
A2.2.3.2 Micro and mini trenching

The use of micro or mini trenching to install services will either be according to a design provided by the Contractor (refer to Clause A2.2.4), design
by the Employer (refer to Clause A2.2.7.6) or in accordance with a performance specification (refer to Section D2.2).

The supervision of the civil engineering component of dry services to be installed in a road reserve shall be in accordance with Clause A2.1.3.7.
The design of temporary works, alternative designs and other designs by the Contractor shall be in accordance with Clauses A2.1.4.1, A2.1.4.2
and A2.1.4.3.
A2.2.5 MATERIALS
The type of duct to be installed shall be as specified in the Contract Documentation. All ducts shall be joined with watertight couplings made from
the same material as the duct.
Unless indicated otherwise in the Contract Documentation ducts shall comply with the following requirements:
A2.2.5.1 Ducts and sleeves

a) Unplasticised Polyvinyl Chloride (U-PVC) ducts
U-PVC ducts and sleeves shall comply with the requirements of Clauses 4.1.1 and 4.1.3 of SANS 2001-DP3.
Normal Duty U-PVC ducts shall be used.
The U-PVC ducts shall have one end plain and chamfered and the other end socketed with an integral socket of the rubber ring type.
b) High Density Polyethylene (HDPE) ducts
(i) HDPE ducts installed by trenching
HDPE ducts to be installed by trenching shall comply with the requirements of SANS 61386-1 and 61386-24.
Normal (code N) Type 450 (Code 450) HDPE ducts shall be used.
As specified in the Contract Documentation the ducts shall either be a Rigid or a Pliable type. Pliable type ducts shall comply with
the bending test requirements of Clause 10.4 of SANS 61386-24 for a minimum bending radius of 20 times the outside diameter.
The ducts shall be joined using suitable compression couplings or sleeve type couplings with rubber sealing O rings as specified in
In addition to the requirements above, HDPE ducts for telecommunications shall comply with certain requirements of ASTM F2160
and ASTM F2176 if they are specified in the Contract Documentation.
(ii) HDPE ducts installed by drilling
As indicated in the Contract Documentation HDPE ducts used for directional drilling shall comply with either of the following:
1. The ducts shall comply with SANS 4427-1 subject to the following:
• Type Smooth wall
• Material PE 100
• SDR series 17
• Pressure rating PN 10
• The ducts shall be joined by butt welding; or
2. The ducts shall comply with the requirements of Clause A12.7.5.2 of Chapter 12 for non-pressure pipes; or
3. The ducts shall comply with the requirements stated in the Contract Documentation.
c) Concrete pipe ducts
Concrete pipes used as ducts shall comply with the requirements of SANS 677. Reinforced Type SC concrete pipes with Spigot and Socket Type
joints with a rolling rubber ring shall be used.
Unless otherwise specified in the Contract Documentation SANS 677 Class 100D pipes shall be used.
d) Fibre-cement (FC) ducts
Fibre-cement ducts shall comply with the requirements of Clauses 4.1.1 and 4.1.4 of SANS 2001-DP3.
LPI (low pressure irrigation) series FC ducts shall be used.
The FC ducts shall be joined using flexible joints of the rubber ring type complying with the requirements of SANS 819.
e) Other duct materials
Where ducts manufactured from materials other than U-PVC, HDPE, concrete or FC are required they shall comply with the requirements as
f) Split ducts
Where required, ducts shall be cut lengthwise into two halves to form split ducts. Split ducts shall normally only be used for providing ducting for
existing services which cannot be severed and threaded through the ducts. The ducts shall be accurately cut longitudinally into two equal halves
and opposite halves shall be matched as sawn. Split ducts shall be placed around the service as required, firmly bound by straps of an approved
material and finally encased in concrete if required.
g) End caps or plugs
End caps or plugs particular to each duct type shall be used to seal the ends of ducts. Where end plugs or caps are not available for a specified
duct type the ends shall be sealed as required by the Contract Documentation.
h) Draw wires and marker tapes
Draw wires and safety marker tapes, if required, shall be in accordance with the details indicated in the Contract Documentation.
A2.2.5.2 Bedding
Bedding for ducts, installed by methods other than by micro or mini trenching, unless otherwise specified in the Contract Documentation, shall be
material of a granular, non-cohesive nature that is free draining, has a maximum aggregate size of 15 mm, a maximum plasticity index (PI) of 6
and has a compaction fraction, determined in accordance with Clause 5.1.4 of SANS 2001-DP1, that does not exceed 0.2.
A2.2.5.3 Backfill
a) Backfill for trenches (excluding micro or mini trenching)
Backfill for ducts installed by methods other than by micro or mini trenching, unless otherwise specified in the Contract Documentation, shall
comply with the requirements of Clause A2.1.5.1.
b) Backfill for micro or mini trenching
Where micro or mini trenching is dealt with in terms of Clause A2.2.7.6 the materials used for bedding, backfilling and reinstatement shall be in
accordance with the details provided in the Contract Documentation.
A2.2.5.4 Cable duct markers

Markers for ducts shall be in accordance with the details provided in the Contract Documentation.
A2.2.5.5 Concrete
All concrete required for duct installation shall comply with the applicable requirements of Section A13.4 of Chapter 13 for strength class (Class
C) concrete as specified in the Contract Documentation.

A2.2.5.6 Masonry
Masonry units shall comply with the requirements of Clause 4.1.11 of SANS 2001-DP3.
A2.2.5.7 Handhole, manhole and access chamber types and covers

a) Handhole, manhole and access chambers
(i) Telecommunications handholes, manholes and access chambers
Telecommunication handholes, manholes and access chambers for ducts shall be in accordance with the details provided in the
(ii) Telecommunications precast handholes
Precast handholes shall comply with the design criteria in the table below:
Table A2.2.5-1: Precast handhole design criteria
Design Parameter Requirement
Limit state of design Ultimate
Imposed Load 100 kN static wheel loads acting vertically on cover
Load Factor 1.6
Material Safety Factors Steel 1.15; Concrete 1.5

Analysis Static, simply supported
Concrete Strength Class C28/35-20
Reinforcing High tensile steel complying with SANS 920
(iii) Telecommunications handholes, manholes and access chambers in dolomite areas

Handholes, manholes and access chambers in dolomite areas shall comply with the requirements of SANS 1936-1 and
SANS 1936-3 for a dry engineering service as defined in SANS 1936-3.
(iv) Other handholes, manholes and access chambers
Handholes, manholes and access chambers for ducts for purposes other than telecommunications shall be in accordance with the
details provided in the Contract Documentation.
b) Covers and frames
(i) Telecommunications covers and frames
Telecommunication covers and frames shall comply with the requirements of SANS 558 and SANS 50124 or alternatively, if so
indicated in the Contract Documentation, be in accordance with EN 124-1 to EN 124-6.
Unless otherwise specified in the Contract Documentation SANS 558 Heavy Duty Class H or SANS 50124 Class D 400 covers and
frames shall be used.
(ii) Other covers and frames
Covers and frames for handholes, manholes and access chambers for ducts for purposes other than telecommunications shall
comply with the requirements of SANS 50124.
Unless otherwise specified in the Contract Documentation Class D 400 covers and frames shall be used.

The requirements in Clause A2.1.6 shall apply to construction equipment used for the installation of ducts.

A2.2.7.1 General
The requirements of Clause A2.1.7 shall apply to trenching for duct installation.
A2.2.7.2 Duct installation by methods other than by micro or mini trenching

a) Trench widths for duct installations
The trench widths for single ducts installed in trenches shall be in accordance with the requirements of Clause A2.1.7.1h).
Unless otherwise specified in the Contract Documentation trench widths where more than one duct is to be installed in a trench shall comply with
the requirements of Clause 4.2.1 and Figure 1 of SANS 2001-DP3.

b) Bedding and compaction of bedding
The bedding for ducts shall comply with the requirements of Clause 4.3 of SANS 2001-DP3. Unless otherwise specified in the Contract
Documentation bedding for ducts shall be compacted to a minimum density of 90 % of MDD in accordance with Clause 5.1.3 of SANS 2001-DP3.
Where permitted in the Contract Documentation the density of the bedding shall comply with the maximum DCP penetration rates indicated in
Clause 5.1.4 and Table 1 of SANS 2001-DP3.
c) Duct laying
Ducts shall be laid in accordance with the requirements of Clause 4.4 of SANS 2001-DP3.
During the installation of pliable ducts, which are supplied in rolls, the ducts shall be straightened to remove any residual “coil memory” by pulling
the duct into the trench from a stationery reel or by laying the duct from a moving reel. Suitable spacers shall be used to keep the ducts in a
straight alignment and, where multiple ducts are to be installed in a single trench, to prevent the ducts from twisting over and around each other.
d) Concrete bedding and encasement
(i) Concrete bedding
Where concrete bedding is required the thickness of the concrete below the duct, the height to which it extends up on either side of
the duct as well as the class of concrete to be used shall be as specified in the Contract Documentation or ordered by the Engineer.
During concreting, ducts or pipes shall be supported on suitably shaped temporary pedestals and strapped down to prevent uplift.
(ii) Concrete encasement
Where specified in the Contract Documentation or ordered by the Engineer ducts shall be encased in concrete in accordance with
the specified dimensions and class of concrete.
During concreting ducts shall be supported on suitably shaped pedestals and strapped down so as to prevent uplift. Poker vibrators
shall be used to ensure that all spaces under and around the pipes are properly filled with concrete. Concrete encasements shall
be cast in one continuous operation until completed.
e) Laying of ducts with other services
Ducts laid with other services shall be in accordance with the requirements of Clause 4.7 of SANS 2001-DP3.
A2.2.7.3 Crossings of other ducts

Ducts crossing other service ducts shall be in accordance with the requirements of Clause 4.8 of SANS 2001-DP3.
A2.2.7.4 Duct markers

a) Lettering
Unless otherwise specified in the Contract Documentation the symbols or lettering in Table A2.2.7-1 shall be used for marking ducts.
Table A2.2.7-1: Symbols for marking ducts
Lettering or
Duct Usage
Symbol
Telecommunications T
Electricity E
Irrigation I
Water (potable) W
Water (non-potable) N
Fire protection F
Gas G
Sewer R
Where applicable different colours shall be used to mark service types. As applicable the colours used shall be in accordance with SANS 10140-
3.
b) Route markers
Where duct route markers are required they shall be installed in accordance with the requirements of the Contract Documentation.
c) Road crossing markers
Where, in accordance with the Contract Documentation, duct or other service crossings have to be marked on kerbs, the position and type of the
ducts or group of ducts crossing shall be marked on the kerbs by cutting the letters, as indicated in Clause A2.2.7.4a), as 75 mm high 35 mm wide
letters 5,0 mm deep into the concrete surface with an angle grinder followed by a number indicating the number of ducts or services at the crossing.
Kerbs where the lettering or symbols have been precast into the kerb face may also be used. The symbol or lettering shall be painted the
applicable colour indicated in Clause A2.2.7.4a).
Where duct crossings cannot be marked on kerbs, markers shall be placed as specified in the Contract Documentation or as ordered by the
Engineer.

A2.2.7.5 Crossings
a) Existing road crossings
The requirements of Clause A2.1.7.2 shall apply where ducts are installed under existing roads by trenching (other than by micro or mini trenching).
b) Railway reserves, bridge and other special crossings
The requirements of Clause A2.1.7.3 shall apply where ducts have to be installed across railway reserves, bridges or in other special
circumstances.
A2.2.7.6 Duct installation by micro and mini trenching

Where micro or mini trenching is used and the work is not dealt with in terms of Clause A2.2.4 or Section D2.2 the installation work, bedding,
backfilling and reinstatement shall be in accordance with the details provided in the Contract Documentation.
A2.2.8 WORKMANSHIP
The requirements of Clause A1.2.8 of Chapter 1 shall apply to the process and acceptance quality control for all services work dealt with in
Section A2.2.
The requirements of Section A12.7 of Chapter 12 shall apply to any ducts installed using trenchless methods.
A2.2.8.1 Tolerances
The installation of ducts installed using trenching (excluding micro or mini trenching) shall comply with the requirements stated below:
a) Horizontal alignment
The maximum deviation of the centre line from the specified position shall be ± 35 mm. Successive deviations from the specified position shall
be in the same direction to avoid creating s-bends. The maximum deviation of the centre line from the specified alignment shall be 1:250 when
taken over any section exceeding 10 m in length.
b) Vertical alignment, grade and level
The maximum deviation from the specified level shall be ± 35 mm.
The maximum deviation of the vertical alignment and grade from the specified alignment, or from the line between duct inverts at successive
manholes or access chambers, as applicable, shall be 1:250 when measured over any section exceeding 10 m length, and all such deviations
shall be gradual. Reverse falls are unacceptable.
c) Compaction and moisture content tolerances
The compaction and moisture content tolerances for bedding shall comply with the requirements of Clause 5.2.2 of SANS 2001-DP3.
A2.2.8.2 Proving ducts

a) Standard proving requirements
Unless otherwise specified in the Contract Documentation the requirements of Clause 5.1.5 of SANS 2001-DP3 shall apply to the proving of ducts.
b) Other duct integrity requirements
Where particular methods for proving ducts or verifying duct integrity, such as verification (air blow), continuity (mandrill) and air pressure testing,
are required, these shall be as specified in the Contract Documentation.

B2.2 DRY SERVICES
CONTENTS
B2.2.1 SCOPE
B2.2.2 DEFINITIONS
B2.2.3 GENERAL
B2.2.5 MATERIALS
B2.2.8 WORKMANSHIP
B2.2.1 SCOPE
Apart from the scope for labour enhancement as described under Section B2.1 no additional scope for labour enhancement is defined under
Section B2.2 for Dry Services.
B2.2.2 DEFINITIONS
Definitions as provided in A2.2.2 apply.
B2.2.3 GENERAL

B2.2.5 MATERIALS


B2.2.8 WORKMANSHIP

C2.2 DRY SERVICES
Section C2.2 should be used in conjunction with Section C2.1 where items are provided to cover the excavation and backfilling of trenches for
ducts and other associated works not included below.
(i) Preamble
Wherever volumetric measurement is required, the volume will be computed from the applicable depths or layer thicknesses and using the
authorised width (W) determined in accordance with the specification.
infrastructure or services damaged by the Contractor’s activities.
pay items.
5. No separate payment will be made for the hauling of all materials where the material is moved over a distance of less than and up to 1,0 km.
For activities in Table C2.2-1 pay items specified in other Chapters or Sections of the specifications, where they relate to work under this Section,

Removal and conservation of topsoil C2.2.4
applicable items
Hauling materials C2.2.4 applicable items
C2.2.4
• Rehabilitation
Placing of top soil and establishment of vegetation C2.2.4 applicable items

C2.2.1 Supply, lay and prove ducts

C2.2.1.1 State for each duct the material type, class, joint type etc. (example HDPE pliable type N450
with compression couplings)
(a) State diameter (example 110 mm diameter (OD)) metre (m)
(b) State diameter (example 160 mm diameter (OD)) metre (m)
C2.2.1.2 State for each duct the material type, class, joint type etc.
(a) State diameter metre (m)
(b) State diameter metre (m)
The unit of measurement shall be the metre of duct supplied and laid.
The tendered rates shall include full compensation for procuring, furnishing and laying and jointing the ducts excluding end plugs and draw wires
as well as for proving the duct as specified, but excluding excavation, bedding, backfilling and encasing which shall be measured and paid for
under the relevant items.
C2.2.2 Extra over item C2.2.1 for the provision of split ducts
C2.2.2.1 State for each duct the material type, class, etc.
C2.2.2.2 State for each duct the material type, class etc.
The unit of measurement shall be the metre of split duct installed and laid.
The unit of measurement shall be full compensation for all the additional costs associated with the provision and installation of split ducts including
any cutting and binding required.
C2.2.3 Lay and prove ducts provided by others
C2.2.3.1 State for each duct to be laid the material type
C2.2.3.2 State for each duct to be laid the material type

The unit of measurement shall be the metre of duct laid.
The tendered rates shall include full compensation for laying the ducts as well as for proving the ducts as specified, but excluding excavation,
bedding, backfilling and encasing the ducts as well as the provision and installation of draw wires and end caps or plugs which shall be measured
and paid for under the relevant pay items. This item will be applicable where the Employer or another service owner supplies the duct materials
free of charge on site for the Contractor to lay and therefore there are no duct materials procurement costs to be included in the rates.

C2.2.4 Bedding for ducts compacted to 90 % of MDD (100 % for sand) using material:
C2.2.4.1 Selected from the excavated trench material cubic metre (m3)
C2.2.4.2 Selected from other excavations on site cubic metre (m3)
C2.2.4.3 Selected from approved borrow areas cubic metre (m3)
C2.2.4.4 Selected from sources provided by the Contractor cubic metre (m3)
C2.2.4.5 From commercial sources
(a) Non-cohesive material (state material type) cubic metre (m3)
(b) Crushed stone material (state material type) cubic metre (m3)
C2.2.4.6 Extra over items C2.2.4.1 to C2.2.4.5 for stabilising material with cement cubic metre (m3)
C2.2.4.7 Cement (state class/type of cement) for stabilising bedding kilogram (kg)
The unit of measurement for items C2.2.4.1 to C2.2.4.5 shall be the cubic metre of bedding material in place after compaction and the quantity
shall be calculated from the specified dimensions of the bedding and backfilling as specified or authorised by the Engineer. The volume occupied
by the ducts shall be subtracted when calculating the volume of bedding.
The unit of measurement for item C2.2.4.6 shall be the cubic metre of bedding material stabilised with cement in place after compaction and the
unit of measurement for item C2.2.4.7 shall be the kilogram of cement used to stabilise the bedding.
The tendered rates for items C2.2.4.1 to C2.2.4.5 shall include full compensation for procuring, furnishing and placing the bedding material under,
alongside and over ducts and for watering and compacting the bedding material to the specified minimum density. The tendered rates for items
C2.2.4.2 and C2.2.4.3 shall include full compensation for the additional cost of excavation in all materials, for loading the material from an
excavation on site or from a borrow pit, for hauling the material within the haul limit of 1,0 km and for unloading the material for placement. The
tendered rate for item C2.2.4.3 shall include full compensation for all operations at borrow pits not subject to any specified separate pay items.
The tendered rates for items C2.2.4.4 and C2.2.4.5 shall include full compensation for the payment of any royalties or charges for procuring and
furnishing the material from sources provided by the Contractor or from commercial sources as well as for transporting the material over an
unlimited haul distance.
The tendered rate for item C2.2.4.6 shall include full compensation for mixing the material with the cement where applicable. The tendered rate
for item C2.2.4.7 shall include full compensation for supplying the cement required for stabilising bedding.
C2.2.5 Concrete for bedding and encasement of ducts
C2.2.5.1 Concrete bedding (state class of concrete) cubic metre (m3)
C2.2.5.2 Concrete encasement of ducts (state class of concrete) cubic metre (m3)
The unit of measurement shall be the cubic metre of concrete placed and the quantity shall be calculated from the dimensions of the excavation
as shown on the drawings or as specified or authorised by the Engineer, irrespective of whether the actual excavation exceeds the specified or
authorised dimensions, minus the volume occupied by the ducts.
The tendered rate shall include full compensation for procuring, furnishing and placing all the materials, formwork and pedestals and for all the
labour and construction equipment necessary to complete the work as specified.
C2.2.6 Duct accessories (markers, marking, draw wires and end caps etc.)
C2.2.6.1 Duct markers (state type) number (No)
C2.2.6.2 Duct marking (state type) number (No)
C2.2.6.3 Draw wires (state type) metre (m)
C2.2.6.4 End caps or plugs (state type) number (No)
C2.2.6.5 Other accessories
(a) State type number (No)
(b) State type metre (m)

The unit of measurement for items C2.2.6.1, C2.2.6.2, C2.2.6.4 and C2.2.6.5(a) shall be the number of markers supplied and installed, marking
completed on kerbs or end caps or plugs or other accessories supplied and installed. The unit of measurement for items C2.2.6.3 and C2.2.6.5(b)
shall be the metre of draw wire or other accessory supplied and installed.

The tendered rates shall include full compensation for the manufacture, delivery and installation of the markers, draw wires, end caps, plugs or
other accessories complete as specified in the Contract Documentation or for completing the marking on kerbs as specified.
C2.2.7 Handholes, manholes and access chambers for ducts
C2.2.7.1 Handholes (state type and drawing reference etc.)
(a) State depth range (example over 1,0 m and up to 1,5 m deep) number (No)
(b) State depth range (example over 1,5 m and up to 2,0 m deep) number (No)
C2.2.7.2 Manholes (state type and drawing reference etc.)
(a) State depth range number (No)
(b) State depth range number (No)
C2.2.7.3 Access chambers (state type and drawing reference etc.)
C2.2.7.4 Other structures
(a) State type, depth range and drawing reference etc. number (No)
(b) State type, depth range and drawing reference etc. number (No)
The unit of measurement shall be the number of handholes, manholes, access chambers or other structures completed as specified. Separate
items will be scheduled for handholes, manholes, access chambers and other structures etc. of each type and of each depth in increments of 0,5
m.
The tendered rates shall include full compensation for all the labour, construction equipment and materials required to complete the handholes,
manholes, access chambers or other structures completed as specified but excluding excavation and backfilling which shall be measured and
paid for separately under the relevant items.
The tendered rates shall exclude the provision and installation of covers and frames which shall be measured and paid for under the relevant
items.
C2.2.8 Covers and frames for duct handholes, manholes and access chambers
C2.2.8.1 State type, strength class and size of cover and frame number (No)
C2.2.8.4 Etc., insert additional items as required number (No)

The unit of measurement shall be the number of covers and frames supplied and installed as specified.
The tendered rates shall include full compensation for the manufacture, delivery and installation of the covers and frames complete as specified
in the Contract Documentation.

C2.2.9 Install duct handhole, manhole and access chamber covers and frames provided by
others

The unit of measurement shall be the number of covers and frames installed as specified.
The tendered rates shall include full compensation for the installation of the covers and frames complete as specified in the Contract
Documentation. This item will be applicable where the Employer or another service owner supplies the covers and frames free of charge on site
for the Contractor to install and therefore there are no cover and frame materials procurement costs to be included in the rates.

D2.2 DRY SERVICES
CONTENTS
D2.2.1 SCOPE
D2.2.2 WARRANTIES FOR PRODUCT OR ELEMENT DESIGN AND INSTALLATION OF PROPRIETARY SYSTEMS
D2.2.3 PERFORMANCE SPECIFICATIONS
D2.2.1 SCOPE
Refer to Clause D2.1.1.
D2.2.2 WARRANTIES FOR PRODUCT OR ELEMENT DESIGN AND INSTALLATION OF

PROPRIETARY SYSTEMS
Where indicated in the Contract Documentation the design and installation of proprietary dry service systems shall require that a warranty of 15
years be supplied by the Contractor. Certification of the installation by a suitable experienced ECSA Registered Professional Engineer or
Technologist is also required together with the warranty.
The warranty form submitted shall include the following details:
a) Description of System / Works Covered.
b) Name and address of Main Contractor.
c) Name of Contact Person.
d) Name and address of Installer.
e) Name of Contact Person.
f) Date of Installation.
g) Duration of Warranty.
h) Start date of Warranty.
i) End date of Warranty.
D2.2.3 PERFORMANCE SPECIFICATIONS

Performance based specifications shall be as specified in the Contract Documentation and shall include the following minimum performance
conditions.
D2.2.3.1 Minimum Performance Specifications for Trenching in the Road Verge

a) No settlement or deformation of trenches will be allowed.
b) No scouring or erosion on trenches will be allowed.
c) Vegetation must be re-established as per surroundings.
D2.2.3.2 Minimum Performance of Micro and Mini Trenching Systems

a) Settlement and or deformation measured under a 3,0 m straight edge across the trench must not exceed 6 mm.
b) No cracking exceeding 3,0 mm along the trench walls will be accepted.
c) No diagonal or transverse cracks exceeding 3,0 mm will be allowed.
d) No trench induced road failures will be allowed.
e) Delamination of trench reinstatement against trench walls will not be accepted.

2.3 WET SERVICES
CONTENTS
A2.3.1 SCOPE
A2.3.2 DEFINITIONS
A2.3.3 GENERAL
A2.3.5 MATERIALS
A2.3.8 WORKMANSHIP

A2.3 WET SERVICES

A2.3.1 SCOPE
Section A2.3 of Chapter 2 covers the civil engineering components for the construction work associated with the installation of wet services (water
supply and waste water (sewerage) pipelines) and ancillary works in road reserves. This Section only covers medium pressure pipelines of
diameter up to 1,0 m for transporting water and sewerage under working pressures of up to 2,5 MPa.
All wet services shall be installed at the locations shown and in accordance with the details shown on the drawings, provided in the Contract
Documentation or as directed by the Engineer.


Section A2.3 of Chapter 2 shall be used in close conjunction specifically with the following standards or specifications which must be available for
use with Section A2.3:
SANS 2001-DP2 Medium pressure pipelines
SANS 2001-DP4 Sewers
SANS 2001-DP6 Below-ground water installations
Other applicable specifications include:
SANS 1294 Precast concrete manhole sections and components
SANS 50124 Gully tops and manhole tops for vehicular and pedestrian areas
A2.3.2 DEFINITIONS
SANS 2001 Definitions - the definitions as indicated in Clause 3 of SANS 2001-DP2, SANS 2001-DP4 and SANS 2001-DP6 shall be applicable.
Where there are any conflicts between the definitions in these SANS specifications and those provided elsewhere in Chapter 2 the latter shall
take precedence.

A2.3.3 GENERAL
Clause A2.1.3.2.

A2.3.4.1 General
The supervision of the civil engineering component of wet services to be installed in a road reserve shall be managed in accordance with Clause
A2.1.3.7. The design of temporary works, alternative designs and other designs by the Contractor shall be in accordance with Clauses A 2.1.4.1,
A2.1.4.2 and A2.1.4.3.
A2.3.4.2 Alternative materials for pipes, fittings and joints

Should the Contractor propose to use pipes and fittings of materials other than those specified in Clause A2.3.5 the Contractor shall submit for
approval detailed specifications including full details of the types of joints and specials the Contractor proposes to use with the pipes and fittings.
The Contractor shall not use such pipes or fittings until written approval for their use has been obtained from the Employer.
A2.3.5 MATERIALS
A2.3.5.1 Sewers
a) Pipes and fittings
Materials for sewer pipes and fittings (excluding rising mains) shall comply with the requirements of Clauses 4.1.1 to 4.1.11 of SANS 2001-DP4.
Materials for rising main sewer pipes and fittings shall comply with the relevant requirements of SANS 2001-DP2.
b) Manholes and chambers
Materials for sewer manholes and chambers shall comply with the requirements of Clause 4.1.12 of SANS 2001-DP4.
Precast concrete manhole sections shall comply with the requirements of SANS 1294 and shall be manufactured using dolomite aggregate. Joints
between precast manhole units shall be of the interlocking, self-centring type. Precast slabs shall comply with the requirements for heavy duty
(HD) slabs.
Step irons shall be of the copolymer polypropylene type with a 12 mm diameter high tensile steel reinforced core and shall be of a length suitable
for fixing in brick, precast concrete or reinforced fibre cement as applicable.
Covers and frames for manholes and chambers for sewers shall comply with the requirements of SANS 50124. Unless otherwise specified in the
Contract Documentation Class D 400 covers and frames shall be used.
c) Materials testing
The requirements of Clause 5.2 of SANS 2001-DP4 shall apply to the testing of sewer materials.
A2.3.5.2 Water Mains

a) Pipes and fittings
Materials for water main pipes and fittings shall comply with the requirements of Clauses 4.1.1 to 4.1.9 of SANS 2001-DP2.
Materials for water mains of diameter up to 160 mm from a water reticulation main to the boundaries of erven shall comply with the requirements
of Clause 4.1.1 of SANS 2001-DP6.
b) Couplings, joints, flanges and accessories
Metallic compression-type pipe couplings, flexible joints for plain-ended steel pipes and flanged pipes and fittings shall, as applicable, comply with
the requirements of Clauses 4.1.10, 4.1.11 and 4.1.12 of SANS 2001-DP2.
c) Valves, inline strainers, backflow devices and fire hydrants
Valves, inline strainers, mechanical backflow-prevention devices and above and below ground fire hydrants shall, as applicable, comply with the
requirements of Clauses 4.1.13, 4.1.14, 4.1.15 and 4.1.16 of SANS 2001-DP2.
d) Manholes, surface boxes, anchor blocks and concrete casings and corrosion protection
Manholes, surface boxes, anchor blocks and concrete casings and corrosion protection shall, as applicable, comply with the requirements of
Clauses 4.1.17 and 4.1.18 of SANS 2001-DP2.
e) Materials testing
The requirements of Clause 5.2 of SANS 2001-DP2 shall apply to the testing of water main materials.
A2.3.5.3 Bedding, fill blanket and backfill material for sewers and water mains
a) Bedding and fill blanket
Bedding and fill blanket materials for sewers and water mains shall comply with the requirements of Clauses 4.1.1 to 4.1.4 and 4.2.3 of SANS
2001-DP1.
The class of bedding (Class A, B, C or D) applicable for each rigid or flexible pipeline shall be as specified in the Contract Documentation.
For the purposes of this Clause A2.3.5.3a) all U-PVC and HDPE pipes shall be treated as flexible pipes.

b) Backfill
Backfill for sewers and water mains shall comply with the requirements of Clause A2.1.5.1.
A2.3.5.4 Marker posts

Markers for sewer and water pipelines shall be in accordance with the details provided in the Contract Documentation.

A2.3.6.1 Pipe handling and rigging equipment
The construction, transportation and rigging equipment used by the Contractor for the handling and placing of pipes shall be of the type
recommended by the pipe manufacturer or supplier. The type of equipment used shall be such that at no time during any handling and placing
operation is any pipe overstressed or physically damaged in any way.
A2.3.6.2 Other construction equipment requirements

The specified requirements in Clause A2.1.6 shall apply to construction equipment used for the installation of wet services.

A2.3.7.1 General
a) Construction requirements
The preparatory work, excavation and bedding for sewer and water pipelines shall comply with the requirements of Clause A2.1.7 and Clauses
4.2.1, 4.2.2 and 4.2.3 of SANS 2001-DP1. Where there are any conflicts between the requirements of the Clause A2.1.7 and the stipulated SANS
clauses the latter shall take precedence.
b) Compaction of bedding and fill blanket
The compaction of bedding material for sewers and water mains shall comply with the requirements of Clause 4.2.3.7 of SANS 2001-DP1 and the
compaction of fill blanket material for sewers and water mains shall comply with the requirements of Clause 4.2.6 of SANS 2001-DP1.
The degree of compaction specified for bedding material in Clause 4.2.3.7 of SANS 2001-DP1 and for fill blanket material in Clause 4.2.6 of SANS
2001-DP1 shall be 100 % of MDD where sand (as defined for fill material in Clause A4.1.5.9 of Chapter 4) is used.
A2.3.7.2 Sewers
a) General construction and pipe laying
The construction and laying of sewers shall comply with the requirements of Clauses 4.2 and 4.3 of SANS 2001-DP4.
b) Construction of manholes and inspection chambers
Manholes and inspection chambers for sewers shall be constructed in accordance with the requirements of Clause 4.4 of SANS 2001-DP4.
c) Concrete casings
Concrete encasement of sewers shall be constructed in accordance with the requirements of Clause 4.5 of SANS 2001-DP4 and Clause 4.2.3.8
of SANS 2001-DP1.
d) Raising or lowering of existing manholes and connecting sewers
The raising or lowering of manholes and the connection of sewers shall be in accordance with the requirements of Clauses 4.6 and 4.7 of SANS
2001-DP4.
A2.3.7.3 Water mains

a) General construction and pipe laying
The construction and laying of water mains shall comply with the requirements of Clauses 4.2 and 4.3 of SANS 2001-DP2.
b) Jointing methods and operations
The jointing of water mains shall comply with the requirements of Clause 4.4 of SANS 2001-DP2.
c) Service connections and setting of valves, specials and fittings
Service connections and the setting of valves, specials and fittings for water mains shall comply with the requirements of Clauses 4.5 and 4.6 of
SANS 2001-DP2.
d) Concrete casings and anchor blocks, thrust blocks and pedestals
The construction of concrete casings, anchor blocks or thrust blocks and pedestals for water mains shall comply with the requirements of Clauses
4.7 and 4.8 of SANS 2001-DP2.
e) Valve and hydrant chambers and manholes
The construction of valve and hydrant chambers and manholes for water mains, unless otherwise specified in the Contract Documentation, shall
comply with the requirements of Clauses 4.9 and 4.10 of SANS 2001-DP2.
f) Lifting and relaying existing pipes
The lifting and relaying of water mains shall comply with the requirements of Clause 4.11 of SANS 2001-DP2.

g) Disinfection of potable water pipelines and corrosion repairs
The disinfection of potable water pipelines and any repairs to the corrosion protection of pipes, specials or joints shall, as applicable, comply with
the requirements of Clauses 4.12 and 4.13 of SANS 2001-DP2.
A2.3.7.4 Excavation, backfilling and re-instatement

The requirements of Clause A2.1.7 shall apply to excavation, backfilling and road re-instatement where sewers or water mains are constructed.
A2.3.8 WORKMANSHIP
A2.3.
The requirements of Section A12.7 of Chapter 12 shall apply to any sewers or water mains installed using trenchless methods.
A2.3.8.1 General
a) Compaction and moisture content tolerances
The compaction and moisture content tolerances for bedding for sewers and water mains shall comply with the requirements of Clause 5.2.2 of
SANS 2001-DP1.
A2.3.8.2 Sewers
a) Tolerances
Unless otherwise specified in the Contract Documentation the requirements of Clause 5.1 of SANS 2001-DP4 shall apply to tolerances for sewers
installed by trenching.
b) Construction tests
(i) General
Unless otherwise specified in the Contract Documentation the requirements of Clause 5.3 of SANS 2001-DP4 shall apply to the
construction tests for sewers. The Contractor shall be responsible for carrying out the specified construction tests and reporting the
results to the Engineer.
(ii) Water tightness of manholes
Where manholes are to be tested in accordance with Clause 5.3.4 of SANS 2001-DP4 the manholes shall be tested, on completion
but before backfilling, for water tightness by completely filling the manhole with water up to the underside of the manhole cover
frame after the pipes leading from manholes have been closed off for the test. The manhole shall be allowed to stand for one hour
to allow initial absorption to take place, after which the water shall be topped up if necessary. After topping up, the water level shall
not drop by more than 20 mm in one hour.
The Contractor shall be responsible for the disposal of the water used in the test by pumping or other approved means.
The Engineer reserves the right to determine whether or not each and every manhole shall be tested. Should it be decided not to
test all manholes, the Engineer will determine which of the manholes shall be tested.
(iii) Camera Inspections
Where required in the Contract Documentation sewers shall be inspected by means of a closed-circuit television camera (CCTV)
on completion of the backfill and manhole construction. The CCTV camera used shall be equipped with inclinometers so that a
pipeline profile can be produced. On completion of the inspection the Contractor shall provide the Engineer with a report in the
agreed electronic or hard format.
A2.3.8.3 Water mains

a) Tolerances
Unless otherwise specified in the Contract Documentation the requirements of Clause 5.1 of SANS 2001-DP2 shall apply to tolerances for water
mains installed by trenching.
b) Construction tests
Unless otherwise specified in the Contract Documentation the requirements of Clause 5.3 of SANS 2001-DP2 or Clauses 5.3 and 5.4 of SANS
2001-DP6, as applicable, shall apply to the construction tests for water mains. The Contractor shall be responsible for carrying out the specified
construction tests and reporting the results to the Engineer.

B2.3 WET SERVICES
CONTENTS
B2.3.1 SCOPE
B2.3.2 DEFINITIONS
B2.3.3 GENERAL
B2.3.5 MATERIALS
B2.3.8 WORKMANSHIP
B2.3.1 SCOPE
Apart from the scope for labour enhancement as described under Section B2.1 no additional scope for labour enhancement is defined under
section B2.3 for Wet Services.
B2.3.2 DEFINITIONS
B2.3.3 GENERAL

B2.3.5 MATERIALS


B2.3.8 WORKMANSHIP

C2.3 WET SERVICES
Section C2.3 should be used in conjunction with Section C2.1 where items are provided to cover the excavation and backfilling of trenches and
other associated works not included below.
(i) Preamble
pay items.

Removal and conservation of topsoil C2.3.3 & C2.3.29
applicable items
Hauling materials C2.3.3 & C2.3.29 applicable items
C2.3.3 & C2.3.29
• Rehabilitation
Placing of top soil and establishment of Section C11.8 of Chapter 11- All
C2.3.3 & C2.3.29 applicable items
vegetation

a) Measurement and Payment items for Sewers (Items C2.3.1 to C2.3.11)
C2.3.1 Supply, lay, joint and test sewers
C2.3.1.1 State for each sewer the pipe material type, class, joint type and the class of bedding etc.
C2.3.1.2 State for each sewer the pipe material type, class, joint type and the class of bedding etc.
C2.3.1.3 Etc, insert additional items as required

The unit of measurement shall be the metre of sewer pipe supplied and laid measured linearly on slopes as laid. No deductions will be made for
specials but deductions will be made for the internal dimensions of manholes. Separate items will be scheduled for pipes of different materials,
diameters, classes, class of bedding and types of joints.
The tendered rates shall include full compensation for procuring, furnishing, laying, bedding and jointing the pipes, making connections into
manholes as well as for testing the pipelines as specified, but excluding excavation, provision of bedding material and backfilling which shall be
measured and paid for under the relevant items. The tendered rates shall also include full compensation for the cutting of pipes, wastage, the
provision of short sections of pipes at manholes and for all work and incidentals required to complete the work as specified.
C2.3.2 Extra over item C2.3.1 for sewer specials
C2.3.2.1 State for each sewer special the type, class, etc.
(a) State diameter number (No)
(b) State diameter number (No)
C2.3.2.2 State for each sewer special the type, class, etc.
C2.3.2.3 Etc., insert additional items as required

The unit of measurement shall be the number of specials installed.
The tendered rates shall include full compensation for procuring, furnishing, laying, installing, bedding, jointing and testing the specials.

C2.3.3 Bedding for sewers (Class B and C) and fill blanket compacted to 90 % of MDD (100 %
for sand)
C2.3.3.1 Bedding using selected granular material
(e) From commercial sources cubic metre (m3)
C2.3.3.2 Selected fill blanket material

C2.3.3 Bedding for sewers (Class B and C) and fill blanket compacted to 90 % of MDD (100 %
for sand)

C2.3.3.3 Extra over items C2.3.3.1(a) to C2.3.3.1(c) and C2.3.3.2(a) to C2.3.3.2(c) for screening cubic metre (m3)
material
The unit of measurement for items C2.3.3.1 and C2.3.3.2 shall be the cubic metre of bedding or fill blanket material in place after compaction and
the quantity shall be calculated from the specified dimensions of the bedding and blanket as specified or authorised by the Engineer. The volume
occupied by the pipes shall be subtracted when calculating the volume of bedding.
The unit of measurement for item C2.3.3.3 shall be the cubic metre of bedding or blanket material screened as instructed by the Engineer and in
place after compaction. The quantity measured shall be increased by including 70 % of the loose volume, measured in stockpile, of the material
screened out and discarded.
The tendered rates shall include full compensation for procuring and furnishing the bedding or fill blanket material and placing the material
alongside and under the pipes and for watering and compacting the bedding or blanket material. The tendered rates for items C2.3.3.1(b),
C2.3.3.1(c), C2.3.3.2(b) and C2.3.3.2(c) shall include full compensation for the additional cost of excavation in all materials, for loading the material
from an excavation on site or from a borrow pit, for hauling the material within the haul limit of 1,0 km and for unloading the material for placement.
The tendered rate for items C2.3.3.1(c) and C2.3.3.2(c) shall include full compensation for all operations at borrow pits not subject to any specified
separate pay items.
The tendered rates for items C2.3.3.1(d), C2.3.3.1(e), C2.3.3.2(d) and C2.3.3.2(e) shall include full compensation for the payment of any royalties
or charges for procuring and furnishing the material from sources provided by the Contractor or from commercial sources as well as for transporting
the material over an unlimited haul distance.
The tendered rate for item C2.3.3.3 shall include full compensation for the additional handling and transport necessary, for screening the material
and for disposing of the material screened out.
Trench backfill (above the fill blanket) will be measured and paid under separate items.
C2.3.4 Concrete for bedding (Class A) and encasement for sewers
C2.3.4.1 Concrete (Class A) bedding (state class of concrete) cubic metre (m3)
C2.3.4.2 Concrete encasement (state class of concrete) cubic metre (m3)

The unit of measurement shall be the cubic metre and the quantity shall be calculated from the dimensions of the excavation as shown on the
drawings or as specified or authorised by the Engineer, irrespective of whether the actual excavation exceeds the specified or authorised
dimensions, less the volume occupied by the pipes.
The tendered rate shall include full compensation for procuring, furnishing and placing all materials, formwork and pedestals and for all the labour
and construction equipment necessary to complete the work as specified including the provision of all the specified expansion and/or construction
joints required.
C2.3.5 Manholes, inspection chambers and cleaning eyes for sewers
C2.3.5.1 Manholes (state type and drawing reference etc.)
(a) State pipe size and depth range number (No)
(b) State pipe size and depth range number (No)
C2.3.5.2 Extra over item C2.3.5.1 for backdrops for manholes (state type and drawing reference etc.)
C2.3.5.3 Inspection chambers (state type and drawing reference etc.)
C2.3.5.4 Cleaning eyes (state type and drawing reference etc.)

C2.3.5 Manholes, inspection chambers and cleaning eyes for sewers
C2.3.5.5 Other structures (state type and drawing reference etc.)

The unit of measurement shall be the number of manholes, inspection chambers, cleaning eyes or other structures completed as specified.
Separate items will be scheduled for manholes, backdrops, inspection chambers and cleaning eyes etc. of each type and of each depth in
increments of 0,5 m. The tendered rates shall include full compensation for all the labour, construction equipment and materials required to
construct the manholes, inspection chambers, cleaning eyes or other structures complete as specified including channels, benching, short pipes
and all flexible connections in accordance with the details indicated in the Contract Documentation. The cost of dealing with any excavation (in
all materials including disposal of surplus) and backfilling with suitable material (including importation of material if required) will be measured
under the relevant items.
The depth category of manholes, inspection chambers, cleaning eyes etc. shall be measured as the difference between the cover level and the
deepest invert level of the structure.
The tendered rates shall include full compensation for all the labour, construction equipment and materials required to complete the manholes,
inspection chambers, cleaning eyes or other structures completed as specified but excluding excavation and backfilling and excluding the provision
and installation of covers and frames which shall be measured and paid for under the relevant items.
C2.3.6 Covers and frames for sewer manholes, inspection chambers and other structures

The unit of measurement shall be the number of covers and frames supplied and installed as specified.
C2.3.7 Sewer accessories (anchor blocks, marker posts, plug stoppers etc.)
C2.3.7.1 Anchor blocks (state type and drawing reference) number (No)
C2.3.7.2 Anchor blocks (state type and drawing reference) cubic metre (m3)
C2.3.7.3 Marker posts (state type and drawing reference) number (No)
C2.3.7.4 Plug stoppers (state type) number (No)
(b) State type number (No)

The unit of measurement for items C2.3.7.1, C2.3.7.3, C2.3.7.4 and C2.3.7.5 shall be the number of anchor blocks, marker posts, plug stoppers
or other accessories supplied and installed. The unit of measurement for item C2.3.7.2 shall be the cubic metre of concrete measured in
accordance with the specified dimensions.
Item C2.3.7.1 will be used where anchor blocks are the same size and where detail drawings are provided for each size or type scheduled. Item
C2.3.7.2 will be used where the anchor blocks vary in size but the relationship between the area of formwork and the volume of concrete is
reasonably consistent.
The tendered rates for items C2.3.7.1, C2.3.7.2, C2.3.7.4 and C2.3.7.5 shall include full compensation for all the labour, construction equipment
and materials required to complete the anchor blocks, plug stoppers or other accessories complete as specified in the Contract Documentation.
The tendered rate for item C2.3.7.3 shall include full compensation for manufacturing, installing and painting the marker posts as specified and
submitting to the Engineer the records of all the marker posts.

C2.3.8 Sewer connections (erf and existing line connections)
C2.3.8.1 Erf connections (state type, depth range and drawing reference)
(a) Connection length (state length in metres) number (No)
(b) Connection length (state length in metres) number (No)
(c) Etc., insert additional items as required number (No)
C2.3.8.2 Erf connections (state type, depth range and drawing reference)
(a) Connection length (state length in metres) number (No)
(b) Connection length (state length in metres) number (No)
(c) Etc., insert additional items as required number (No)
C2.3.8.3 Erf connections to sewer manholes
(a) State type, depth range, etc. Sum
(b) State type, depth range, etc. Sum
C2.3.8.4 Connecting sewers to existing manholes
(a) State position, specification and drawing reference etc. Sum
(b) State position, specification and drawing reference etc. Sum
(c) Etc. insert additional items as required Sum
C2.3.8.5 Breaking into an existing sewer and building a new manhole
(a) State position, specification and drawing reference etc. Sum
(b) State position, specification and drawing reference etc. Sum
(c) Etc. insert additional items as required Sum

The unit of measurement for items C2.3.8.1 and C2.3.8.2 shall be the number of erf connections supplied and installed. The unit of measurement
for items C2.3.8.3, C2.3.8.4 and C2.3.8.5 shall be the sum per connection or manhole completed as specified.
Separate items will be listed for erf connections measured at different depths and for different lengths. The depth will be that of the main sewer
at the point of connection. The size, type, class and treatment of the junction and bend shall be the same as for the connection pipe. The tendered
rate for items C2.3.8.1 and C2.3.8.2 shall cover the cost of excavation in all materials, bedding and backfilling (including importation of suitable
material if required), disposal of surplus materials, supply and installation of a junction with the erf connection entering the main sewer line flush
with the soffit of the main sewer, a 45 degree bend and the end cap.
The tendered sum for item C2.3.8.3 shall cover the cost of adapting a standard manhole to accommodate the erf connection pipe and the supply
and installation of the end cap.
The tendered sum for item C2.3.8.4 shall include full compensation for excavation, making an opening in the existing manhole, installing new
pipes in the new opening, for breaking out and modifying the channelization inside the manhole to suit the new pipe layout, ensuring the water
tightness of the new connection, supplying all the necessary materials, removing surplus material and debris, all labour and equipment required
to make the connection, and liaison with the local authorities.
The tendered sum for item C2.3.8.5 shall include full compensation for excavation, building a new manhole over the sewer, breaking into the
existing sewer, building the channelization under wet conditions, ensuring the water tightness of the new connection, supplying all the necessary
materials, removing surplus material, all labour and equipment required to make the connection, and liaison with the local authorities but excluding
the cost of the cover and frame.
C2.3.9 Raising and lowering existing sewer manholes
C2.3.9.1 Raising manholes
(a) State manhole type and drawing reference and height raised number (No)
(b) State manhole type and drawing reference and height raised number (No)
C2.3.9.2 Lowering manholes
(a) State manhole type and drawing reference and height lowered number (No)

C2.3.9 Raising and lowering existing sewer manholes
(b) State manhole type and drawing reference and height lowered number (No)
The unit of measurement for items C2.3.9.1 and C2.3.9.2 shall be the number of manholes raised or lowered as specified or shown on the
drawings.
The tendered rates shall include full compensation for all the labour, construction equipment and materials required to raise or lower the manholes
as specified including removing the cover and frame, demolishing the top of the manhole if required, rebuilding the manhole and setting and
grouting the cover and frame to the new level specified.
C2.3.10 Testing of sewer manholes number (No)

The unit of measurement shall be the number of manholes tested and passed, irrespective of the depth and type of manhole.
The tendered rate shall include full compensation for all labour, construction equipment and materials necessary, including the supply and disposal
of water and for carrying out the tests as specified.
C2.3.11 CCTV camera inspections
C2.3.11.1 State pipe diameter metre (m)
C2.3.11.2 State pipe diameter metre (m)

The unit of measurement shall be the metre of each diameter of sewer inspected by CCTV camera and which has met the specified tolerances.
The tendered rates shall include full compensation for the provision of all labour, equipment and materials required for the provision, installation,
calibration and operation of the equipment used for inspecting the pipeline and the provision of a report and pipeline profile in the agreed electronic
or hard format.
Note:
Pay items C2.3.12 to C2.3.20 have been deliberately left for use for additional contract specific sewer related pay items inserted via the
b) Measurement and Payment Items for Water Mains (Items C2.3.21 to C2.3.36)
(i) Corrosion protection
The rates for pipes, valves, specials and couplings for items C2.3.21 to C2.3.26 shall also cover the cost of mortar lining and
sheathing, mortar encasing, wrapping and all other corrosion protection as may be specified. The rates shall also cover the costs
of all measures deemed necessary to safeguard the specified protection against any damage during transportation, stacking,
storage, installation and bedding and backfilling etc and the rates shall also cover the costs of any repairs required as a result of
any such damage.
(ii) Temporary Valves etc
Payment for the supply or loan of temporary valves, end caps, blank flanges, or other isolating devices ordered by the Engineer in
terms of Clause 5.3.1.1 of SANS 2001-DP2 will be made at daywork rates or at rates to be agreed by the Engineer, unless the
method of payment for the work has been dealt with in the Contract Documentation and a suitable special item included in the
schedule.
C2.3.21 Supply and lay water mains complete with couplings

C2.3.21.1 State for each water main the pipe material type, class, coupling type and the class of
bedding etc.

C2.3.21.2 State for each water main the pipe material type, class, coupling type and the class of
bedding etc.

The unit of measurement shall be the metre of water main pipe supplied and laid measured linearly on slopes as laid. No deductions will be made
for specials or valves.
The tendered rates shall include full compensation for procuring, furnishing and laying the pipes complete with couplings, including handling,
inspecting, transporting, laying, jointing, bedding, cutting and testing the pipes as specified, but excluding excavation, provision of bedding material
and backfilling which shall be measured and paid for under the relevant items.

C2.3.22 Extra over item C2.3.21 for supplying and fixing water main fittings or specials
complete with couplings
C2.3.22.1 State for each water main fitting or special the type, class etc.
C2.3.22.2 State for each water main fitting or special the type, class etc.

The unit of measurement shall be the number of water main fittings or specials, complete with couplings, installed.
The tendered rates shall be full compensation for procuring, furnishing, laying, handling, fixing, inspecting, transporting, bedding and jointing and
testing the fittings or specials including couplings and including the cost of cutting of pipes.
No extra payment over and above the rates will be made in respect of any additional cutting, turning, and jointing of pipes required for the location
of specials etc. in the positions given on the drawings. Unless specific provision is made in the schedule, no separate payment will be made for
the supply and fitting of any additional joints and jointing materials which may be required for the connection of shortened pipe lengths.
C2.3.23 Extra over item C2.3.21 for supplying and fixing water main valves
C2.3.23.1 State for each water main valve the type, class etc.
C2.3.23.2 State for each water main valve the type, class etc.

The unit of measurement shall be the number of valves installed.
The tendered rates shall be full compensation for procuring, furnishing, laying, handling, fixing, inspecting, transporting, bedding and jointing and
testing the valves including couplings and including the cost of cutting of pipes.
No extra payment over and above the rates will be made in respect of any additional cutting, turning, and jointing of pipes required for the location
of valves, etc. in the positions given on the drawings. Unless specific provision is made in the schedule, no separate payment will be made for
the supply and fitting of any additional joints and jointing materials which may be required for the connection of shortened pipe lengths.

C2.3.24 Extra over item C2.3.21 for cutting of pipes and the supplying and fixing of extra
couplings
C2.3.24.1 State for each water main the pipe material type and coupling type
C2.3.24.2 State for each water main the pipe material type and coupling type

The unit of measurement shall be the number of pipes cut.
The tendered rates shall include full compensation for the cutting of the pipe and of supplying and fitting the additional coupling and, if required
by the Engineer, the delivery of unused off-cuts to the Employer’s office or store.

C2.3.25 Extra over items C2.3.21, C2.3.22 and C2.3.23 for supplying and installing joints with
machined collars and special couplings
C2.3.25.1 State for each water main the pipe collar and special coupling type
C2.3.25.2 State for each water main the pipe collar and special coupling type

The unit of measurement shall be the number of machined collars and special couplings supplied and installed.
The tendered rate shall cover the additional cost of providing pipes with machined collars and slip-on couplings as scheduled and of installation
complete as specified.
C2.3.26 Supplying and installing pipes, specials and valves on short pipe runs
C2.3.26.1 State for each short run water main the pipe material type, class and class of bedding etc.
(a) State pipe diameter and length metre (m)
(b) State pipe diameter and length metre (m)
C2.3.26.2 State for each short run water main the fitting, bend or special type, class etc.

Short pipe runs that include frequent bends or other specials, or both (as, for instance, for a deviation of a water main under a road or round a
bridge) will be measured in terms of the quantities of scheduled items such as bends, tees, reducers, valves, and stated lengths (or stated
approximate lengths) of straight pipe. The unit of measurement for pipes shall be the metre of water main pipe supplied and installed. The unit
of measurement for specials or valves installed shall be the number installed.
The tendered rates shall include full compensation for the provision of each pipe, special, and valve and, as applicable, the fixing anchoring, or
bedding of them in the manner required in terms of the Contract Documentation. The tendered rates shall exclude excavation, provision of bedding
material and backfilling which shall be measured and paid for under the relevant pay items.
C2.3.27 Extra over item C2.3.21 for encasing (wrapping) joints
C2.3.27.1 State for each water main the number of joints to be encased (wrapped)

Where steel or ductile iron fittings and joints are to be subject to corrosive soil conditions and the Contract Documentation indicates that they have
to be treated in accordance with the note included in Clause 4.1.18 of SANS 2001-DP2 the unit of measurement shall be the number of joints
encased as specified.
The tendered rates shall include full compensation for procuring and furnishing the materials and for all the construction equipment and labour
required to encase the joints as specified.

C2.3.28 Installation of hydrants and water meters
C2.3.28.1 Describe hydrant type number (No)
C2.3.28.2 Describe water meter type number (No)

The unit of measurement shall be the number of hydrants, water meters or other special items supplied and installed.
The tendered rate for the installation of hydrants shall cover the cost of the supply and installation of all materials from and including the tee (and
its joints) on the main up to and including the hydrant outlet. The pipes required will be measured separately. The tendered rates shall exclude
anchor blocks and any covers and frames which will be measured separately.
The tendered rate for the installation of water meters shall cover the supply and installation of the water meters including all reducers, adaptors,
couplings and other fittings required to complete the installation on the specified size of pipeline.

C2.3.29 Bedding for water mains (Class B and C) and fill blanket compacted to 90 % of MDD
(100 % for sand)
C2.3.29.1 Bedding using selected granular material
C2.3.29.2 Selected fill blanket material

C2.3.29.3 Extra over items C2.3.29.1(a) to C2.3.29.1(c) and C2.3.29.2(a) to C2.3.29.2(c) for screening cubic metre (m3)
material
The unit of measurement for items C2.3.29.1 and C2.3.29.2 shall be the cubic metre of bedding or fill blanket material in place after compaction
and the quantity shall be calculated from the specified dimensions of the bedding and blanket as specified or authorised by the Engineer. The
volume occupied by the pipes shall be subtracted when calculating the volume of bedding.
The unit of measurement for pay C2.3.29.3 shall be the cubic metre of bedding or blanket material screened as instructed by the Engineer and in
place after compaction. The quantity measured shall be increased by including 70 % of the loose volume, measured in stockpile, of the material
screened out and discarded.
The tendered rates shall include full compensation for procuring and furnishing the bedding or fill blanket material and placing the material
alongside and under the pipes and for watering and compacting the bedding or blanket material. The tendered rates for items C2.3.29.1(b),
C2.3.29.1(c), C2.3.29.2(b) and C2.3.29.2(c) shall include full compensation for the additional cost of excavation in all materials, for loading the
material from an excavation on site or from a borrow pit, for hauling the material within the haul limit of 1,0 km and for unloading the material for
placement. The tendered rate for items C2.3.29.1(c) and C2.3.29.2(c) shall include full compensation for all operations at borrow pits not subject
to any specified separate pay item.
The tendered rates for items C2.3.29.1(d), C2.3.29.1(e), C2.3.29.2(d) and C2.3.29.2(e) shall include full compensation for the payment of any
royalties or charges for procuring and furnishing the material from sources provided by the Contractor or from commercial sources as well as for
transporting the material over an unlimited haul distance.
The tendered rate for item C2.3.29.3 shall include full compensation for the additional handling and transport necessary, for screening the material
and for disposing of the material screened out.
Trench backfill (above the fill blanket) will be measured and paid under separate items.

C2.3.30 Concrete for bedding (Class A) and encasement for water mains
C2.3.30.1 Concrete (Class A) bedding (state class of concrete) cubic metre (m3)
C2.3.30.2 Concrete encasement (state class of concrete) cubic metre (m3)

The unit of measurement shall be the cubic metre and the quantity shall be calculated from the dimensions of the excavation as shown on the
drawings or as specified or authorised by the Engineer, irrespective of whether the actual excavation exceeds the specified or authorised
dimensions, less the volume occupied by the pipes.
and construction equipment necessary to complete the work as specified. The tendered rate shall also include full compensation for forming any
specified and/or construction joints that may be required.
C2.3.31 Manholes, valve and hydrant chambers etc. for water mains
C2.3.31.1 Manholes (state type and drawing references etc.)

C2.3.31.2 Valve chambers (state valve type (gate valve, single or double air valve etc.) and drawing
references etc.)
C2.3.31.3 Hydrant chambers (state type etc. and drawing references etc.)
C2.3.31.4 Other structures (state type etc. and drawing reference etc.)

The unit of measurement shall be the number of manholes, valve and hydrant chambers or other structures completed as specified.
Separate items will be scheduled for manholes, valve or hydrant chambers etc. of each type and of each depth in increments of 0,5 m. The
tendered rate shall cover the cost of construction of manholes, valve and hydrant chambers etc. complete in accordance with the details indicated
in the Contract Documentation. The cost of dealing with any excavation (in all materials including disposal of surplus) and backfilling with suitable
material (including import of material if required) will be measured under the relevant items.
The depth category of manholes and chambers etc. shall be measured as the difference between the cover level and the deepest invert level of
the structure.
The tendered rates shall include full compensation for all the labour, construction equipment and materials required to complete the manholes,
valve and hydrant chambers or other structures completed as specified but excluding excavation and backfilling and excluding the provision and
installation of covers and frames which shall be measured and paid for under the relevant items.

C2.3.32 Covers and frames for water main manholes, valve and hydrant chambers and other
structures
C2.3.32.1 Describe manhole or chamber and state type of cover and frame number (No)

The unit of measurement shall be the number of covers and frames supplied and installed.

C2.3.33 Water main accessories (anchor or thrust blocks, pedestals or marker posts etc.)
C2.3.33.1 Anchor or thrust blocks (state type and drawing reference) number (No)
C2.3.33.2 Anchor or thrust blocks (state type and drawing reference) cubic metre (m3)
C2.3.33.3 Pedestals (state type and drawing reference) number (No)
C2.3.33.4 Pedestals (state type and drawing reference) cubic metre (m3)
C2.3.33.5 Marker posts or blocks (state type and drawing reference) number (No)

The unit of measurement for items C2.3.33.1, C2.3.33.3, C2.3.33.5 and C2.33.3.6 shall be the number of anchor or thrust blocks, pedestals or
marker posts or blocks or other accessories supplied and installed. The unit of measurement for items C2.3.33.2 and C2.3.33.4 shall be the cubic
metre of concrete placed.
Items C2.3.33.1 and C2.3.33.3 will be used where thrust blocks or pedestals are the same size and where detail drawings are provided for each
size or type scheduled. Items C2.3.33.2 and C2.3.33.4 will be used where the thrust blocks or pedestals vary in size but the relationship between
the area of formwork and the volume of concrete is reasonably consistent.
The tendered rates for item C2.3.33.1, C2.3.33.2, C2.3.33.3, C2.3.33.4 and C2.3.33.6 shall include full compensation for all the labour,
construction equipment and materials required to complete the anchor or thrust blocks, pedestals or other accessories complete as specified in
the Contract Documentation. The tendered rate for item C2.3.33.5 shall include full compensation for manufacturing, installing and painting the
marker posts or blocks as specified and submitting to the Engineer the records of all the marker posts or blocks.
C2.3.34 Connections to existing water mains
C2.3.34.1 State connection details number (No)

Connections to existing water mains will be measured by the number of connection points.
The tendered rates shall include full compensation for the cost of locating, exposing and backfilling the water main, liaising with the authority
concerned to arrange for turning off the water, cutting into the pipe, dealing with water, cutting pipes to fit, including turning if necessary, and the
supply and fitting of long collar repair couplings to complete the connection and, if required, the temporary sealing and anchoring of pipe ends for
testing purposes and subsequent removal of seals and anchors. The specials required to make the connection will be measured separately.
C2.3.35 Raising and lowering existing manholes or valve or hydrant chambers
C2.3.35.1 Raising manholes or valve of hydrant chambers
(a) State manhole type and drawing reference and height raised number (No)
(b) State manhole type and drawing reference and height raised number (No)
C2.3.35.2 Lowering manholes or valve or hydrant chambers
(a) State type and drawing reference and height lowered number (No)
(b) State type and drawing reference and height lowered number (No)
The unit of measurement for items C2.3.35.1 and C2.3.35.2 shall be the number of manholes or valve or hydrant chambers raised or lowered as
specified or shown on the drawings.
The tendered rates shall include full compensation for all the labour, construction equipment and materials required to raise or lower the manholes
or valve or hydrant chambers as specified including removing covers and frames, any demolition required, rebuilding and setting and grouting the
covers and frames to the new levels specified. This pay item does not cover the costs of the lowering of pipes.

C2.3.36 Disinfection of potable water pipelines
C2.3.36.1 State diameter of pipe disinfected metre (m)
C2.3.36.2 State diameter of pipe disinfected metre (m)

The unit of measurement shall be the metre of potable water pipeline disinfected as specified.
The tendered rate shall include full compensation for all labour, construction equipment, chemicals and other materials necessary for disinfecting
pipes as specified. Where pipes have to be disinfected more than once due a fault of the Contractor, the cost of the additional water required
shall be for the Contractor’s account.

D2.3 WET SERVICES
CONTENTS
D2.3.1 SCOPE
D2.3.2 GENERAL
D2.3.1 SCOPE
There are no specific items in this Section.
Where applicable, details are provided in the Contract Documentation.

2.4 ENERGY AND OTHER SERVICES
CONTENTS
A2.4.1 SCOPE
A2.4.2 DEFINITIONS
A2.4.3 GENERAL
A2.4.5 MATERIALS
A2.4.8 WORKMANSHIP

A2.4 ENERGY AND OTHER SERVICES

A2.4.1 SCOPE
Section A2.4 of Chapter 2 covers the civil construction work associated with the installation in road reserves of street lighting and electric power
and other energy services (gas and fuel pipelines) and any other types of services (not dealt with elsewhere in Chapter 2) as specified in the
It should be noted that Section A2.4 of Chapter 2 only covers excavation and backfilling work for electric power and street lighting services. The
section does not cover the supports (poles, struts, stays, pylons, gantries etc.) or the cables or other electric plant associated with such
infrastructure which would be installed by specialist contractors or subcontractors with the appropriate skills, experience and equipment required
to do such work.
Work on certain energy (gas and fuel pipelines and higher voltage (HV, EHV and UHV)) services, due to their nature, is specialised and therefore
few standard specifications and conditions are considered to be applicable to such work. All energy services shall therefore be installed at the
locations shown, and in accordance with, the specifications and details shown on the drawings or provided in the Contract Documentation or as
directed by the Engineer.
The purpose of Section A2.4 is therefore partly to provide a structured framework for the Contract Documentation for civil construction work related
to energy services or any other types of services not dealt with elsewhere in Chapter 2.

SANS 4437-1 Plastics piping systems for the supply of gaseous fuels- Polyethylene (PE)
Part 1: General
Part 2: Pipes
Part 3: Fittings
Part 5: Fitness for purpose of the system
SANS 10198-5 The selection, handling and installation of electric power cables of rating
not exceeding 33 kV Part 5: Determination of thermal and electrical
resistivity of soil
SANS 10198-8 The selection, handling and installation of electric power cables of rating
not exceeding 33 kV Part 9: Cable laying and installation
SANS 10225 The design and construction of lighting masts
SANS 10280 Overhead power lines for conditions prevailing in South Africa
SANS 10280-1 Overhead power lines for conditions prevailing in South Africa Part 1: Safety

ISO/TS 10839 Polyethylene pipes and fittings for the supply of gaseous fuels - Code of
practice for design, handling and installation
A2.4.2 DEFINITIONS
Extra high voltage (EHV) - the set of nominal voltage levels that are used in power systems for bulk transmission of electricity in the range 220
kV < Un < 400 kV.
Fuel - see Gas and Fuel.
Gas and fuel - any hydrocarbon gas fuel transported by pipeline.
Gaseous fuel - fuel which is in a gaseous state at a temperature of 15oC and a pressure of 1 bar.
High voltage (HV) - the set of nominal voltage levels that are used in power systems for bulk transmission of electricity in the range 44 kV < Un
< 220 kV.
Low voltage (LV) - the set of nominal voltage levels that are used for the distribution of electricity and whose upper limit is generally accepted to
be an a.c. voltage of 1 000 V (or a d.c. voltage of 1 500 V). Note that in certain fields of technology, for example electric motors and mining,
voltages up to and including 1 100 V are traditionally regarded as low voltage.
Medium voltage (MV) - the set of nominal voltages that lie above low voltage and below high voltage in the range 1 kV < Un < 44 kV.
Ultra-high voltage (UHV) - the set of nominal voltage levels that are used in power systems for bulk transmission of electricity in the range Un >
400 kV.
A2.4.3 GENERAL
Clause A2.1.3.2.

The requirements of Clause A2.1.4 shall be applicable.
A2.4.5 MATERIALS
A2.4.5.1 General
All materials for energy services or other types of services (not specified elsewhere in Chapter 2 or in this Section) shall be in accordance with the
standards or specifications indicated in the Contract Documentation.
A2.4.5.2 Bedding for electric power cables

Only sandy clay or loam soil with an acceptable thermal resistivity (not exceeding 1.2K.m/W determined in accordance with SANS 10198-5) shall
be used for bedding for electric power cables. Sea or river sand, ash, chalk, peat, clinker or clayey soil shall not be used. The use of crusher
dust/sand is acceptable. The maximum aggregate size for bedding material shall be 5,0 mm and, if required, bedding material shall be sieved to
meet that requirement. Where no suitable bedding material is available on site, the Contractor shall import material from other sources and make
all the necessary arrangements to do so.
A2.4.5.3 Backfill for electric power cables

Backfill for electric power cables, unless otherwise specified in the Contract Documentation, shall be a material that complies with the requirements
of Clause A2.1.5.1.
A2.4.5.4 Electric power warning tape

All cables shall be covered with a continuous brightly coloured corrosion proof (PVC or PE) electrical warning tape. The tape shall have a minimum
thickness of 0,8 mm and a minimum width of 150 mm. The tape shall be yellow, marked with the words "ELECTRIC CABLE / ELEKTRIESE
KABEL" in red letters at least 70 mm in height. These markings shall not be more than 0,5 m apart.
A2.4.5.5 Electric power concrete slab protection

Where indicated in the Contract Documentation concrete protective slabs shall be installed on electric power cable bedding, approximately 100 mm
above MV cables, and shall be a minimum 300 mm wide and 50 mm thick. The slabs shall be constructed of class C16/20-14 concrete. Each
slab shall be reinforced with 8,0 mm diameter mild steel bars with at least two longitudinal bars per 300 mm wide slab and transverse bars at a
maximum 200 mm spacing.

A2.4.5.6 Electric power cable markers
Unless otherwise indicated in the Contract Documentation cable markers shall consist of concrete blocks in the shape of truncated pyramids,
approximately 300 mm high, 150 x 150 mm at the top and 250 x 250 mm at the bottom. Recessed letters, a minimum of 50 mm high, shall be
cast into the tops of the blocks with the wording "ELECTRIC CABLE” as well as direction arrows and the cable voltage rating.
A2.4.5.7 Polyethylene pipes for gaseous fuels

Unless otherwise indicated in the Contract Documentation when polyethylene pipes are used for the supply of gaseous fuels they shall comply
with the requirements of SANS 4437-1, 4437-2, 4437-3 and 4437-5.

A2.4.6.1 General
All equipment for the construction of energy services or other types of services (not dealt with elsewhere in Chapter 2) shall be in accordance with
the standards or specifications indicated in the Contract Documentation.
A2.4.6.2 Other requirements

The specified requirements in Clause A2.1.6 shall apply to construction equipment used for the installation of energy services.

A2.4.7.1 General
All construction of energy services or other types of services (not dealt with elsewhere in Chapter 2), unless specified otherwise in Section A2.4,
shall be in accordance with the standards or specifications indicated in the Contract Documentation.
Except as indicated in Clause A2.4.7.2 the requirements of Clause A2.1.7 shall apply mutatis mutandis to the installation of electric power cables.
Electric cable installation shall comply with the requirements of SANS 10198-8.
The specialist electrical or communications contractor or subcontractor shall be attendance during all critical trenching, bedding, backfilling or
compaction activities.
A2.4.7.2 Trenching for electric power cables

a) Excavation
Trenches shall be excavated in straight sections as shown on the drawings or as instructed by the Engineer and shall be excavated to the
dimensions indicated in this specification. The bottom of the trench shall have smooth contours and shall have no sharp dips or rises which may
cause tensile forces in the cable during backfilling. Where levels are not specified the level of the bottom of the trench shall follow the contours
of the final ground level. Where the excavation is in excess of the required depth the excavation shall be backfilled and compacted with approved
material to the required depth. Prior to cable laying the trench shall be inspected thoroughly and all objects likely to cause damage to the cables
during or after laying shall be removed.
Where ground conditions are likely to reduce the maximum current carrying capacities of cables or adversely affect cable insulation or where the
cables are likely to be subjected to chemical or other damage or electrolytic action e.g. soil drenched with hydrocarbon based solvents such as
oil, the Engineer shall be notified before installing the cables so that the Engineer can issue any necessary instructions.
b) Trench dimensions
(i) Trench width
The width for cable trenches shall be as specified in the Contract Documentation.
The minimum trench width for cables shall be 450 mm. The specified width shall apply to the total trench depth. The width shall be
increased where more cables are installed to allow for the spacings stipulated in Clause A2.4.7.2b)(iii) with the minimum trench
width allowing for a working space on each side of the cables measured between the centre of the outside cables and the side of
the trench. Unless otherwise indicated in the Contract Documentation the working space width shall be 200 mm.
Where trenches change direction or where cable slack is to be accommodated, the Contractor shall ensure that the requirements
of the relevant specification regarding the bending radii of cables are met when determining trench widths.
Excavations in excess of the predetermined widths will not be measured for payment and excavations narrower than these widths
will only be allowed with the written approval of the Engineer.
(ii) Trench Depth
Trench depths shall be determined in accordance with cable laying depths and bedding thickness.
Unless otherwise indicated in the Contract Documentation cables shall be installed at the following minimum depths below final
ground level:

Table A2.4.7-1: Minimum telecommunication and electric power cable depths
Cable Type Minimum Installation Depth
Telecommunication cables 600 mm
Low voltage (LV) services cables 800 mm
Low voltage (LV) feeder cables 800 mm
Medium voltage (up to 11 kV) 1000 mm
Medium voltage (greater than 11 kV) 1200 mm
Other voltages and cable types In accordance with the
Contract Documentation
All voltages and cable types where, due to security 1000 mm
reasons, concrete bedding or other protection is
specified
All cable depth measurements shall be made to the top of the cable when laid directly in ground or to the top of the duct or sleeve
where these are provided. The above depths shall apply to the top layer where cables are installed in layers. The Contractor may
only deviate from the above depths provided prior authority in writing has been obtained from the Engineer. In the event that the
minimum depths cannot be achieved the cables shall be protected with a suitable concrete covering.
The depth of cable ducts or pipes beneath railway lines or roads shall be not less than 1,1 m below the formation or road level as
applicable.
Trenches shall be excavated to a total depth which take into account the bedding thickness requirements indicated in Clause
A2.4.7.3.
(iii) Cable spacing
Cables installed in the same trench shall be laid parallel to each other with the following minimum spacings between cables (for the
purposes of the list below MV refers to voltages up to 11kV).
Table A2.4.7-2: Minimum electric power cable spacings
Cable Type Minimum Cable Spacing
LV/LV 2 cable diameters (minimum 25 mm)
LV/MV 150 mm
MV/MV 200 mm
LV/MV/PILOT 1 cable diameter
Where MV and LV cables have to be installed in the same trench, both shall be laid at a depth of 800 mm and then covered with
200 mm of bedding material. The bedding shall then be placed and compacted and the trench then backfilled and compacted layer
by layer.
Cables for telephones, communication systems and other low voltage systems (less than 50V) shall be separated from power cables
by at least 1,0 m horizontally. All control or pilot cables without a lead sheath and steel armouring shall be laid at least 300 mm
from power cables.
Cables shall not be installed on top of each other unless separating layers are specified. The minimum spacing between layers
shall be 200 mm. Where cables are to be installed on top of each other the work shall be done in accordance with the details
provided in the Contract Documentation.
Cable laying shall be planned so that as far as possible cables do not cross each other. Where crossing is unavoidable, a vertical
separation of not less than 150 mm shall be provided for cables of the same voltage and of 300 mm for cables of differing voltage.
A2.4.7.3 Bedding for electric power cables

The bottom of the trench shall be filled across the full width with a layer of bedding material and levelled off. After cable laying a further layer of
bedding shall be placed above the cable. The bedding under joints shall be fully consolidated to prevent subsequent settling.
Normal bedding thicknesses for electric cables shall be as follows (unless otherwise stated the dimension indicated is the bedding thickness
required above and below the cable/s):
Table A2.4.7-3: Bedding thickness for electric power cables
Cable Type Minimum Bedding
Thickness
MV and LV cables in soft earth 75 mm
MV cables in other conditions (gravel / hard rock) 150 mm
LV kiosk feeder cables in other conditions (gravel / hard rock) 150 mm
LV service connection cables in other conditions (gravel / hard rock) 150 mm (above)
100 mm (below)
Refer to Clause A2.4.7.7 where security risks dictate the use of concrete bedding.

A2.4.7.4 Backfilling for Electric Power Cables
The Contractor shall not commence with the backfilling of trenches without prior notification to the Engineer so that the cable installation may be
inspected. Such an inspection will not be unreasonably delayed. Should the Contractor fail to give a timeous notification, the trenches shall be
re-opened at the Contractor's cost.
All loose stones or any other materials likely to cause damage to cables shall be removed from trenches or from any excavated material that may
be used for backfill, before backfilling commences.
Backfilling of trenches shall be in layers not exceeding 150 mm thick. Compaction of backfill shall achieve the following field densities:
• In areas not subject to vehicular traffic loads 90 % of MDD
• In areas subject to vehicular traffic loads 93 % of MDD
Backfilling across grassed or landscaped areas may be in layers of 300 mm thickness. Removal and replacement of plants, shrubs, grass, etc.
including care until growth is re-established, may be required. After completion of the work the route of the trench shall be neatly finished off and
cleared. All stones bigger than 25 mm, as well as all loose organic material and rubble, shall be removed.
Where trenches cross a road carriageway and/or footways the reinstatement of the pavement layers and surfacing shall be in accordance with
the requirements of Clause A2.1.7.2.
A2.4.7.5 Electric power cable warning tape

All cables shall be covered with an electrical warning tape. The tape/s shall cover all the cables installed in a trench. Where two tapes are laid
side by side they shall overlap by at least 20 mm. The warning tapes shall be installed 400 mm above the upper cable in a trench.
A2.4.7.6 Electric power cable concrete slab protection

Where the minimum installation depths cannot be achieved due to the crossing of other services and the service cannot be crossed underneath
cables must be protected by additional slabs in accordance with SANS 10198-8.
Where cables cross other services such as water pipes and sewage pipes or where it is possible that the cable may be damaged as a result of
excavation by others, the cable shall be protected by means of reinforced concrete slabs.
The slabs shall protect the cable for a distance of 1,0 m on either side of the crossing or vulnerable area.
The slabs shall be installed 150 mm above the cables to be protected.
A2.4.7.7 Electric power cable concrete bedding

Cables installed in a road reserve, where the risk of cable theft is considered to be significant, shall, if specified in the Contract Documentation,
be encased in class C16/20-20 concrete. The bottom of the trench must be filled with a 150 mm thick concrete layer, the cable installed while the
concrete is still wet, and then the cable covered with a further 150 mm thick concrete layer. The concrete must extend all the way to inside the
pole or kiosk where the cables terminate.
A2.4.7.8 Electric power cable markers

Cable markers shall, if specified in the Contract Documentation, be provided along cable routes. Cable markers, where specified, shall be installed
on the surface along the underground routes and shall project 35 mm above normal ground level unless the projected markers could be a hazard
to pedestrian or other traffic in which case they shall be installed flush with the surface. Cable markers shall be installed at the beginning and end
of a cable run (e.g. where a cable enters a substation or building), at all changes of direction, above all joints, above cable duct entries and exits
and at intervals not exceeding 50 m along the cable route. The position of cable markers shall be indicated on the record drawings.
A2.4.7.9 Steel supporting structures

Steel supporting structures for lighting and other energy services, such as lighting masts on concrete median barriers shall be carried out in
accordance with the requirements of the Contract Documentation and in accordance with the applicable sections of this standard specification.
All work shall adhere to the specified levels, alignments and tolerances.
A2.4.7.10 Overhead power lines

Overhead power lines shall be constructed in accordance with the requirements of SANS 10280 and SANS 10280-1.
A2.4.7.11 Polyethylene pipes for gaseous fuels

Unless indicated otherwise in the Contract Documentation or indicated on the drawings polyethylene pipes for gaseous fuels shall be installed in
accordance with the requirements of ISO/TS 10839.
A2.4.8 WORKMANSHIP
A2.4.
A2.4.8.1 General
The quality of materials and workmanship for energy services or other types of services (not dealt with elsewhere in Chapter 2) shall be in
accordance with the standards or specifications indicated in the Contract Documentation.

A2.4.8.2 Tolerances
The excavation, backfilling and bedding for the installation of cables shall be controlled in line and level to ensure that the cable/s installed meet
all statutory or specified cable depth, cover and clearance requirements.
A2.4.8.3 Lighting Poles

The tolerances for the installation of free-standing masts for lighting shall comply with the requirements of Clause 7.11 of SANS 10255. Testing
shall comply with the requirements of Clause 7.12 of SANS 10255.

B2.4 ENERGY AND OTHER SERVICES
CONTENTS
B2.4.1 SCOPE
B2.4.2 DEFINITIONS
B2.4.3 GENERAL
B2.4.5 MATERIALS
B2.4.8 WORKMANSHIP
B2.4.1 SCOPE
Apart from the scope for labour enhancement as described under Section B2.1, no additional scope for labour enhancement is defined under
Section B2.4 for Energy and Other Services.
B2.4.2 DEFINITIONS
B2.4.3 GENERAL

B2.4.5 MATERIALS


B2.4.8 WORKMANSHIP

C2.4 ENERGY AND OTHER SERVICES
Section C2.4 should be used in conjunction with Section C2.1 where items are provided to cover the excavation and backfilling of trenches and
other associated works not included below.
(i) Preamble
pay items.
(iv) Items to be Measured and Paid for Using Items Specified Elsewhere in the Specifications

Removal and conservation of topsoil C2.4.1
applicable items
Hauling materials C2.4.1 applicable items
C2.4.1
• Rehabilitation
Placing of top soil and establishment of vegetation C2.4.1 applicable items

C2.4.1 Bedding for electric power cables using material:
C2.4.1.1 Selected from the excavated trench material cubic metre (m3)
C2.4.1.2 Selected from other excavations on site cubic metre (m3)
C2.4.1.3 Selected from approved borrow areas cubic metre (m3)
C2.4.1.4 Selected from sources provided by the Contractor cubic metre (m3)
C2.4.1.5 From commercial sources
(a) Uncrushed material (state material type) cubic metre (m3)
(b) Crushed stone material (state material type) cubic metre (m3)
The unit of measurement for items C2.4.1.1 to C2.4.1.5 shall be the cubic metre of bedding material in place after compaction and the quantity
shall be calculated from the specified dimensions of the bedding and backfilling as specified or authorised by the Engineer.
The tendered rates for items C2.4.1.1 to C2.4.1.5 shall include full compensation for procuring, furnishing and placing the bedding material under,
alongside and over cables. The tendered rates for items C2.4.1.2 and C2.4.1.3 shall include full compensation for the additional cost of excavation
in all materials, for loading the material from an excavation on site or from a borrow pit, for hauling the material within the haul limit of 1,0 km and
for unloading the material for placement. The tendered rate for item C2.4.1.3 shall include full compensation for all operations at borrow pits not
subject to any specified separate pay item.
The tendered rates for items C2.4.1.4 and C2.4.1.5 shall include full compensation for the payment of any royalties or charges for procuring and
furnishing the material from sources provided by the Contractor or from commercial sources as well as for transporting the material over an
unlimited haul distance.
C2.4.2 Concrete for bedding and encasement for electric power cables
C2.4.2.1 Concrete bedding (Class C16/20-20 concrete) cubic metre (m3)
C2.4.2.2 Concrete encasement of cables (Class C16/20-20 concrete) cubic metre (m3)
The unit of measurement shall be the cubic metre of concrete placed, and the quantity shall be calculated from the dimensions of the excavation
as shown on the drawings or as specified or authorised by the Engineer, irrespective of whether the actual excavation exceeds the specified or
authorised dimensions.
and construction equipment necessary to complete the work as specified.
C2.4.3 Cable laying accessories (warning tape, protection slabs, markers etc.)
C2.4.3.1 Electrical warning tape (state type) metre (m)
C2.4.3.2 Concrete slab protection (state type and dimensions etc) metre (m)
C2.4.3.3 Cable markers (state type) number (No)
(a) State type metre (m)

The unit of measurement for items C2.4.3.1, C2.4.3.2 and C2.4.3.4(a) shall be the metre of electrical warning tape, concrete slab protection or
other accessories supplied and installed. The unit of measurement for items C2.4.3.3 and 2.4.3.4(b) shall be the number of cable markers or
other accessories supplied and installed.
The tendered rates shall include full compensation for the manufacture, delivery and installation of the electrical warning tape, concrete slab
protection, cable markers or other accessories complete as specified in the Contract Documentation.

D2.4 ENERGY AND OTHER SERVICES
CONTENTS
D2.4.1 SCOPE
D2.4.2 GENERAL
D2.4.1 SCOPE
There are no specific items in this Section.
Where applicable, details are provided in the Contract Documentation.

South Africa
COTO
Officials


CHAPTER 3: DRAINAGE
October 2020

FOREWORD

Published by:

industry.
Document versions:
Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 3: DRAINAGE ........................................................................................................................................ 3-1
3.1 DRAINS ......................................................................................................................................................... 3-1
PART B: LABOUR ENHANCEMENT ................................................................................................................................................................. 3-8
PART D: GUARANTEES & COMPLIANCE CERTIFICATES ........................................................................................................................... 3-17
3.2 CULVERTS ................................................................................................................................................ 3-18

3.3 CONCRETE KERBING AND CHANNELING, ASPHALT BERMS, CHUTES, DOWNPIPES, AS WELL AS
CONCRETE, STONE PITCHED AND GABION LININGS FOR OPEN DRAINS ................................................. 3-39
CHAPTER 3: DRAINAGE
3.1 DRAINS
CONTENTS
A3.1.1 SCOPE
A3.1.2 DEFINITIONS
A3.1.3 GENERAL
A3.1.5 MATERIALS
A3.1.8 WORKMANSHIP

A3.1 DRAINS
A3.1.1 SCOPE
Drainage under this Section covers mainly open drains as well as subsoil drains and their associated works. This Section covers the work required
for adequate surface, subsurface and piped drainage to ensure that the road and ancillary structures drain freely and without damage or risk to
infrastructure and road users. It covers all work, both rehabilitation and new work, in connection with the excavation and construction of open
drains, channels, subsoil drainage and banks and dykes at the locations and to the sizes, shapes, grades and dimensions as shown on the
drawings, or as specified by the Engineer.
It also covers the cleaning of existing open drains, as well as the test flushing of existing and new subsoil drains and the repairing of existing
subsoil drainage. In particular circumstances this work may be executed outside the road reserve.
Also covered is the clearing of existing culverts, including the removal of all materials which have accumulated in and around inlet and outlet
structures and in the barrels of the culverts, which is likely to adversely affect the operation of the drainage system.
Excluded are the lining of any drains such as with concrete, stone pitching, vegetation, synthetic and alternative materials and wired mesh, which
are covered under Section A11.1 of Chapter 11.
A3.1.2 DEFINITIONS
No specific definitions.
A3.1.3 GENERAL
No specific items.

None applicable unless specific specifications have been accepted as proposed by the Contractor or included into the Contract Documentation.
A3.1.5 MATERIALS
A3.1.5.1 General material specifications
The material specifications are the required specifications for the materials as provided, placed and/or processed in final position for the drainage
elements.
It is the Contractor’s responsibility to ensure that the materials delivered and utilised for the drainage elements shall meet the specified
requirements.

Materials removed under this Section from existing works, except where excavated materials are specified to be reused or disposed of, or except
where provision has been made in Part C for their reuse or specific disposal, shall be deemed to be the property of the Contractor.
A3.1.5.2 Subsoil Drainage Materials

a) Pipes
The pipes for subsoil drainage systems to be used shall be either unplasticised PVC (U-PVC) pipes or high-density polyethylene (HDPE) pressure
pipes with smooth inner bore and internal diameters as indicated on the drawings or in the Contract Documentation. Pipes shall have the specified
internal diameter, which shall be not less than 100 mm (except for composite subsoil drainage systems), and shall be one of the following types:
• U-PVC pipes complying with SANS 791 for solid wall pipes (category-heavy duty) or SANS 1601 for structured wall pipes (stiffness class 350),
which may be slotted or perforated for drainage in-flow as specified. The carrier portions of pipes shall not be slotted or perforated.
• HDPE pipes to be used with aggregate filled subsoil drains systems shall be slotted or perforated for groundwater in-flow as specified. HDPE
pipes shall have a ring stiffness >450 kPa and slotted / perforated with 30 % solid invert and of twin wall construction, with a smooth inner
bore and ribbed outer wall. The carrier portions of pipes shall not be slotted or perforated.
The size of perforations in perforated pipes shall in all cases be 8,0 mm in diameter ± 1,5 mm and the number of perforations per meter shall
not be less than 26 for 100 mm diameter pipes and 52 for 150 mm diameter pipes. Perforations shall be spaced in two rows for 100 mm pipes
and as shown on the drawings for 150 mm pipes.
Slotted pipes shall have a nominal slot width of 8,0 mm ± 1,5 mm. The arrangement of slots shall be 240 degrees of the circumference with
the flow channel invert of 120 degrees. The total slot area shall not be less than that required for perforated pipes.
• Pipes for geocomposite fin type subsoil drainage systems may be HDPE, extruded into an open lattice wall structure with a wall thickness of
minimum of 5,0 mm. Of the circumference area, 70 % shall consist of an open structure, and the remaining 30 % being the invert, shall be
solid. Openings in the mesh structure shall be greater than 5,0 mm but less than 12 mm in size. Alternatively, U-PVC or HDPE pipes as
specified above for aggregate filled drains may be used. The water infiltration capacity of the all types of pipes under a 200 mm static head
shall not be less than 20 litres per second per metre pipe length (l/s/m) for 65 mm diameter pipes; not less than 55l/s/m for 100 mm diameter
pipes and not less than 80l/s/m for 150 mm diameter pipes.
All slotted or perforated pipes shall retain 30 % of the pipe invert for conveyance of drainage and the top of the pipes shall externally carry a
longitudinal marker line to ensure that pipes are correctly placed during construction.
Pipes without slots or perforations required for conveying ground water from the subsoil drainage proper, to the point of discharge, shall be U-
PVC or HDPE pipes of the types specified.
Pipes must be stored in a shaded area without exposure to direct sunlight, and stacked according to supplier’s instructions.
b) Natural and crushed permeable material
Natural permeable filter materials for subsoil drainage shall consist of sand and/or crushed stone of suitable grading. Natural permeable materials
shall conform to the following requirements:
Sand used for natural permeable material shall be clean, hard sand obtained from approved sources. The sand shall comply with the requirements
of SANS 1083, Table 1: Sand, and shall be either coarse, medium or fine grade as specified. The nominal maximum particle size for the various
grades shall be as shown in Table A3.1.5-1, and all sand shall be clean with not more than 5 % of the material passing through the 0,075 mm
sieve.
Table A3.1.5-1: Natural permeable materials: Sand
Grade Nominal maximum particle size (mm)
Coarse 5
Medium 2
Fine 0,2
Crushed stone used for natural permeable material shall comply with the requirements given in SANS 1083: Table 3: Stone for Concrete, and
shall be either be fine (14 mm nominal size) or coarse (20 mm nominal size) as specified. Crushed stone shall be clean with not more than 5,0 %
of the material passing through the 0,075 mm sieve.
When no suitable sand and/or crushed stone is available from borrow pits or designated quarries, the Engineer may require that it be procured
from commercial sources.
c) Geotextiles
Should the use of geotextiles be specified in subsoil drainage systems, or as filter separation blankets, or for any other purposes, it shall comply
with the requirements as specified in Section A12.11 of Chapter 12.
(i) Testing
The Contractor shall, at his own cost, submit a certificate by an approved laboratory to prove compliance with specified tests as
stated in Chapter 20. Alternatively, verifiable testing by the supplier may be submitted for approval to the Engineer.
The tests to be carried out on geotextiles relate to the material and the method of manufacture and are mainly to ascertain that the
correct grade and type of geo-textile is supplied, and that the material is equivalent in quality to that specified for use in the works.
This includes geotextile qualities regarding soil retention; permeability; clogging; durability and strength. Compatibility testing can
be done for filtration using the ASTM D5101 - Measuring the Soil-Geotextile System Clogging Potential by the Gradient Ratio.
d) Polymer film sheeting
Plastic for subsoil drainage systems to be used shall be polymer film type sheeting of 150 to 250 micron (0,15 to 0,25 mm) thickness, complying
with SANS 952-1.
A3.1.5.3 Geocomposite drainage systems (fin type drains)

Geo-composite in-plane drains (fin type drains) shall consist of a drainage core connected to a drainage pipe, all of which shall be enclosed in a
geotextile as specified, required to fully enclose the drainage core.

The drainage core shall act as a flow net and shall include the physical characteristics as listed in Table A3.1.5-2.
Table A3.1.5-2: Physical characteristics of fin type geo-composite drain
Properties Units Core Test Method
Polymer Type HDPE
Mass (minimum) g/m² 500 SANS 9864/ISO 9864
Thickness (minimum under 2 kPa) mm 4,0 SANS 9863-1/ISO 9863-1
Tensile Strength (minimum machine & kN 5,0 SANS 1525/ISO 10319
across)
Minimum Discharge Capacity of Fin type Geo-composite drain
Discharge Capacity (under 50 kPa) l/s/m² ˃0,1 ISO 12958
The geotextile shall comply with the properties in Section A12.11 of Chapter 12. The Engineer shall specify the grade and type of geotextile
required to fully enclose the drainage core.
a) Mesh-structured pipe component of geo-composite drain.
The drainage pipe used for this purpose shall meet the following requirements:
Pipes for in-plane subsoil drainage systems shall have an internal diameter of 65 or 100 mm, as specified. The pipe shall be manufactured from
High Density polyethylene (HDPE) with a solid 5,0 mm wall thickness. It shall be extruded in an open lattice wall structure, with 70 % of the
diameter consisting of open area and a 30 % solid area along the invert. Perforations in the open structure of the pipe shall be greater than 5,0
mm but less than 12 mm.
The infiltration capacity of the pipe, without geotextile, under a 200 mm static head shall not be less than the following:
• For 65mm ID pipe = 20 litres per metre per second
• For 100mm ID pipe = 55 litres per metre per second
b) Geo-composite strip drains or prefabricated vertical drains (wick drains):
Geo-composite strip drains shall consist of a drainage core enclosed in geotextile.
The drainage core shall act as a flow net and combined with the geotextile shall include the physical characteristics as listed in Table A3.1.5-3.
Table A3.1.5-3: Physical characteristics of the geo-composite strip drain
Properties Units Composite Strip Drain Test Method
Drain Width mm 100 250 330
Geotextile As specified in Clause A3.1.5.2c)(i)
Manufacture
Core HDPE
Mass Core g/m² 80 200 220 SANS 9864 /
ISO 9864
Minimum under
Thickness Geotextile & Core mm 4,5 4,5 4,5
250kPa
Minimum Discharge Capacity Of Geo-composite strip drain
under 20kPa l/s 0,1 0,07 0,10
ISO 12958 /
Discharge Capacity under 50kPa l/s 0,05 0,06 0,09
ASTM D4716
under 250kPa l/s 0,02 0,03 0,04
c) Geo-composite Panel Drains

Geo-composite panel drains shall consist of a rigid corrugated plastic core of a flat pipe configuration with a well-defined invert enclosed in a
geotextile and shall be classified according to the following minimum requirements as listed in Table A3.1.5-4.
Table A3.1.5-4: Physical characteristics of the geo-composite panel drain
Properties Units Geo-composite Panel Drain Test Method
Drain Depth mm 170 315 450
Drain Width mm ˃40 ASTM D2122
Slot Size mm 2,8 x 30
Compressive Strength kPa ˃200 ASTM D2412:11
Mod
Geotextile As specified in A3.1.5.2c)(i)
Manufacture
Core HDPE
Geotextile
Minimum Through Flow Under 100mm head l/s/m² 230 AS3706.9-12
Minimum Tensile Strength Machine kN/m 9,5 AS3706.2-12
Minimum Trapezoidal Tear N 300 AS3706.3-12
Pore Size O95W μm 110 AS3706.7-14
Geo-composite panel drain
Minimum Discharge Under 200kPa at0,01
l/s 0,35* 0,65 0,95 ASTM D4716:14
Capacity(vertical) gradient

A3.1.5.4 Concrete
All concrete work shall be carried out in accordance with the requirements in Section A13.4 of Chapter 13 of these specifications, read together
with the provisions of this Section. Cement shall comply with SANS 50197-1 for CEM I or CEM II with a strength class of 32.5 or greater, and a
rate of strength gain of N or greater.
Unless the Contractor obtains the concrete from a commercial concrete supplier, the Contractor shall be responsible for providing suitable
materials, determining the mix proportions and manufacturing the concrete of the required quality to comply with SANS 50206.
The mix design shall be based upon obtaining an average concrete compressive strength sufficiently above the specified characteristic compressive
strength so that, considering the expected variability of the concrete and test procedures, no more than 5,0 % of strength tests will be expected to
fall below the specified characteristic compressive strength.
Where concrete is supplied by a commercial source outside the direct control of the Engineer, the concrete supplier shall ensure compliance with
the requirements of SANS50206 (SANS878), and the Contractor shall take full responsibility to implement acceptance control testing in accordance
with the specification.
All concrete mixed on the site of works shall be weigh-batched unless the Contractor can demonstrate to the Engineer that his method of
proportioning the concrete ingredients consistently produces uniform concrete, which meets the strength requirements.
Concrete shall be properly mixed to a uniform consistency. The total period between the times that the cement is placed into the mix until mixing
starts shall not exceed 15 minutes.
Concrete shall be so transported to its final position that segregation or loss of any of the ingredients or contamination will be prevented and that
the mix is of the required workability at the point and time of placing. It shall be protected against rain, heat, direct sunlight and/or evaporation by
means of covers. No additional water may be added in transit or where delivered or placed.
Once the casting of concrete has begun, it shall be carried out in a continuous process between construction joints. Concrete shall be placed
within 60 minutes from the start of mixing. This time may be extended by the Engineer where a retarding admixture has been used. All excavations
and other contact surfaces of an absorbent nature such as timber formwork shall be damp but no standing water shall be permitted to remain on
these surfaces. The formwork shall be clean on the inside.
A3.1.5.5 Mesh for subsoil drain outlets

Where specified on the drawings, the outlets of subsoil drains shall be covered by mesh built into the outlets or other material as specified.
Galvanized woven wire mesh shall comply with the requirements of SANS 675.

The Contractor shall submit his plant and equipment list for excavating, stockpiling, if specified, loading, hauling and any temporary works as part
of his method statement to perform the different elements of the drainage works.

A3.1.7.1 Classification of Materials
All excavations for open drains and subsoil drainage systems shall be excavated in the position and to the required dimensions. Overbreak in
width or depth, unless specified by the Engineer, shall be filled and compacted by the Contractor and shall not be measurable for payment.
All excavations under this Chapter shall be classified as follows for payment purposes:
Hard material: Material which cannot be excavated except by drilling and blasting, or with the use of pneumatic tools or
mechanical breakers, and
Boulders exceeding 0,1 m3; where more than 40 % by volume of any material consists of boulders, each
exceeding 0,1 m3 in size, the volume of material so defined shall be classified as hard material
Existing stabilised road Existing layer material which has been stabilised (irrespective of stabilising agent) and requires careful cutting
layers: and excavation without damage to surrounding existing road layers, by whichever method.
Soft material: All material not classified as hard material or existing stabilised road layers shall be classified as soft material.
A3.1.7.2 Open Drains

Open-drain excavation shall involve the excavation of open drains and channels, including channels to direct the course of water flow, all as
detailed in the Contract Documentation or as directed by the Engineer.
The classification criteria for establishing the type of drain excavation is set out in Table 3.1.7-1.

Table A3.1.7-1: Open drain excavation classification criteria
Trapezoidal Trapezoidal Road prism
Drain V-shaped V-shape
shape / channel shape / channel drains
Bottom width < 4,0 m n/a ≥ 4,0 m n/a
All new or
Side-slope Steeper than existing drains
(steepest side-slope not applicable 1v : 4h Flatter than within the road
n/a prism namely
is the determining (n/a) (v=vertical; 1v : 4h
slope) h=horisontal) median drains,
side drains and
drains on cut or
fill slopes.
Top width n/a ≤ 5,0 m n/a > 5,0m

Bottom width Steepest side- Bottom width Steepest side-
Classification criteria
only slope or top width only slope or top width
Open drain Open drain Designated excavation Chapter 4 Shape, trim
Drain classification
excavation excavation Chapter compliant material and/or clean
for excavation
Chapter 3 3 Excavation to spoil Chapter 5 Chapter 5
Where clearing and/or grubbing is required for new open drains to be constructed, it shall be executed as specified in Section A1.6 of Chapter 1.
Open drains shall be constructed within 5 % true to line, grade and cross-section and shall be so maintained for the duration of the contract. Open
drains shall at all points be graded to flow in the direction of intended flow without low points where water may pond.
Care shall be taken to avoid excavation below the required grades for the open drains and any excavation carried out below the required grade
shall be backfilled with material of minimum G7 quality and compacted to at least 93 % of MDD by the Contractor at no cost to the Employer.
Material resulting from the excavations for open drains shall be used in the construction of fills, banks and dykes, or for other purposes, or shall
be disposed of to spoil, all as specified by the Engineer.
In respect of material resulting from open-drain excavation and not taken to spoil but used elsewhere in the construction of the works, payment
will be made for open drain excavation as well as for any item of temporary or permanent construction built from such material. Material from open
drain excavation, which is taken to spoil will be paid for as open-drain excavation only. Where specified by the Engineer that existing open drains,
but excluding new open drains constructed by the Contractor, shall be cleared and, where necessary, shaped by removing the sediment and
trimming the floors and side slopes, the specified requirements for constructing new open drains shall apply similarly to clearing and shaping
existing open drains.
Any concrete, stone pitched or wire mesh enclosed lining of open drains shall be done in accordance with the requirements of Clause A11.1.5 of
Chapter 11.
The Contractor shall remove all materials that will adversely affect the performance of the constructed drainage, including all silt, sediment,
driftwood, vegetation, debris and rubble that have accumulated in and around the culvert inlet and outlet structures and in the culvert barrels.
Unless such work forms part of specified work to rehabilitate or clear existing drains, no payment shall be made for such work, as it shall be
deemed to form part of normal finishing and trimming operations. All materials resulting from the clearing operations shall be disposed of at
specified locations. The clearing shall preferably be done with hand tools in order to prevent damage to existing drainage and other structures.
All structures damaged by the Contractor shall be repaired and made good at no cost to the Employer, all as instructed by the Engineer.
Measurement and payment in respect of the clearing and shaping of existing open drains, as classified in Table A3.1.7-1 shall be made under the
relevant items in Sections C3.1, C4.2 of Chapter 4 and C5.2 of Chapter 5.
A3.1.7.3 Banks and Dykes

Where specified by the Engineer that clearing and/or grubbing is required for new banks and dykes to be constructed, it shall be executed as
specified in Section A1.6 of Chapter 1.
Mitre banks, catchwater banks and dykes shall be constructed of approved soil or gravel obtained from cut and/or open drain excavation or, if no
suitable material can be obtained from those sources, from suitable approved alternative sources, and be placed in such a way that the water will
flow in a shaped open drain or on the natural ground and against the bank. Where open drains with bank/dyke are constructed as combination,
excavation and fill shall be measured and paid for separately.
The banks and dykes shall be properly compacted to 93 % of MDD in layers not exceeding 150 mm.
The appearance of the completed mitre bank shall present an even, tight surface.
If so specified, mitre banks facing shall be constructed of hand packed stone pitching as detailed in Clause A11.1.7 of Chapter 11.
A3.1.7.4 Subsoil drainage

a) Construction of subsoil drainage systems
(i) With natural permeable material
Trenches required for subsoil drainage systems shall be excavated to the dimensions and gradients shown on the drawings or as
specified by the Engineer, neatly trimmed to line and level. In case of deeper excavations, or excavations in unstable or saturated
ground, the Contractor shall take all necessary steps to assure the safety of such excavations and to ensure that specified lines
and levels are complied with. Such steps may entail the provision of temporary shoring or battering of side slopes. All such steps
shall be deemed to be included in the tendered rates for excavations.

A layer of natural permeable material of the grade and thickness as shown on the drawings shall be placed on the bottom of the
trench and be lightly tamped and finished to the required gradient.
Pipes of the type and size specified shall then be firmly bedded on the natural permeable material, true to line and level, and be
coupled in accordance with the pipe manufacturer’s requirements. Thereafter the trench shall be backfilled with the specified
natural permeable material to such height above the pipes as shown on the drawings or as specified by the Engineer. The natural
permeable material shall be lightly compacted and trimmed to the required level. Further layers of finer specified natural permeable
material shall then be placed, in layers not exceeding 300 mm in thickness at a time lightly compacted and finished to an even
surface, as specified by the Engineer. The remainder of the trench, if any, shall be backfilled with approved impermeable material
and as specified by the Engineer, in layers not exceeding 150 mm, and compacted to at least the same density as the surrounding
material. The trench shall be specially protected against the ingress of water until the impermeable layer has been completed. The
width of the backfill as measured for payment shall not exceed the specified width of the trench.
The total thickness of each type of natural permeable material shall be carefully controlled for thickness and level, using suitable
spacers where required. When successive layers are placed, the lower layer shall not be walked on and, as far as possible, shall
not be disturbed. Care shall be taken to prevent the contamination of natural permeable material during construction of the subsoil
drainage system and all natural permeable material contaminated by soil or silt shall be removed and replaced by the Contractor
at his own cost.
Perforated and slotted pipes shall be joined by means of couplings, the provision and installation of which shall be deemed to be
covered under the rates for the pipes. Perforated pipes shall be laid with perforations either at the top or bottom as specified on
the drawings, specifications or specified be the Engineer.
The higher end of each subsoil drainage pipe shall be sealed off with a loose concrete cap of class C20/25-20concrete, as shown
on the drawings and at the lower end, the pipe shall be built into a concrete head wall providing a positive outlet, or it shall be
connected to structures for stormwater pipes or concrete culverts. The complete system, together with head walls, shall be
constructed in one process starting at the lower end. No continuous section of subsoil drain shall be longer than 80m long and
cleaning eyes constructed in accordance with the details shown on the drawings shall be spaced at a maximum spacing of 80m.
Any section of a subsoil drainage system constructed of pipes without perforations or slots shall be backfilled with impermeable
backfill material as described herein. Where suitable, the excavated material may be used for backfilling.
(ii) With polymer film lining to trenches for subsoil drainage systems
Where shown on the drawings or specified by the Engineer, trenches for subsoil drainage systems shall be lined with approved
polymer film sheeting 0,15 mm or 0,25 mm thick as shown on the drawings or specified in the Contract Documentation. The
polymer film sheet shall cover the bottom of the trench and shall extend upwards on both sides for as far as may be specified by
the Engineer in each particular case, in order to form a waterproof channel. At joints the polymer film sheeting shall be heat-welded
together or lapped by a minimum of 200 mm. Lapping shall be in direction of the flow of water.
Pipes of the type and size specified shall be installed as specified, true to level and grade, and be coupled in accordance with
requirements.
When backfilling the trench with the specified natural permeable material, care shall be taken not to displace or damage the
polymer film lining in any way. The use of plastics other than polymer film will be considered, provided that the material is proven
to the Engineer to be of equal or better quality.
(iii) With geotextiles
Where specified that geotextiles shall be used for lining in subsoil drainage systems, it shall be procured, furnished and installed
as specified and shown on the drawings. The lining shall not be displaced or damaged in any way when the trench is being filled
with the specified natural permeable material. The geotextile shall be lapped both longitudinally and transversely by at least 300
mm or as specified by the manufacturers. The longitudinal lap shall be positioned on top of the box forming the drain and shall be
stitched together with plastic/galvanised wire or strong synthetic thread at one metre intervals. The transverse lap shall be in the
direction of flow.
Pipes of the type and size specified shall be installed as specified, true to line and grade, and be coupled in accordance with the
pipe manufacturer’s requirements.
(iv) With composite in-plane drainage systems
Wherever specified, composite in-plane drainage systems shall be constructed in accordance with the details shown on the
drawings and in accordance with the manufacturer’s requirements. The elements of the system shall be assembled above ground
in manageable lengths, and all exposed surfaces shall be sealed with an approved geo-fibre seal. The trench sides shall be vertical,
and the composite in-plane system shall be installed against the side through which the subsoil flow is expected. The trench shall
then be backfilled with natural permeable sand, which shall be saturated with water after placement, up to the prescribed level.
The upper part of the trench shall be backfilled with impermeable material, which shall be compacted to the density of the
surrounding material, in layers not exceeding 100 mm in thickness.
(v) With alternative drainage systems
Alternative drainage systems, where relevant, shall be specified and detailed in the Contract Documentation.
(vi) Proving of pipes in subsoil drainage systems
The laying of slotted/perforated pipes supplied in coils shall be subject to providing a method statement which includes proving
during installation, to ensure that the invert is accurately installed.
On completion of the pipe laying and prior to backfilling over pipes, all pipe joints shall be surveyed as proof of their installation to
line and grade. After backfilling, the pipes shall be proved by pulling through a cylindrical cleaning brush followed by a wooden
mandrill ± 400 mm long and 5,0 mm in diameter less than the bore of the pipe. Proving of installed pipes shall not be paid for
separately and the cost thereof shall be deemed to be included in the rate tendered for laying the pipe.
b) Test flushing
Final acceptance of longitudinal subsoil drains constructed by the contractor will be subject to satisfactory test flushing after completion and
installation of the rodding eye inlets. Flushing tests shall be carried out in the presence of the Engineer's representative by flushing the drain and

metering the outflow to ensure the drain is clear of blockage. Should blockages be apparent the Contractor shall locate and clear the obstruction
and repeat the test.
Proving of the lack of obstructions may also be undertaken by camera equipment inserted into the subsoil drains should this be specified by the
Engineer.
A3.1.7.5 Manholes, outlet structures and cleaning eyes

Outlet structures and cleaning eyes for subsoil drainage systems shall be constructed in accordance with the details shown on the drawings and/or
indicated in the Contract Documentation. Manholes for subsurface drains shall be constructed as detailed and measured under Section A3.3.
The end of each subsoil outlet shall be marked with a suitable visible marker clearly indicating the position of each subsoil outlet structure in
accordance with the details on the drawings or as specified by the Engineer.
A3.1.7.6 As-Built Drawings

The Contractor shall furnish the Engineer with a detailed set of relevant drawings verifying and recording the subsoil drainage systems as installed.
Such records shall include accurate coordinates of all starting points, bends, cleaning eyes, manholes, junctions and outlet structures, including
the depth below surface level at each such point.
A3.1.8 WORKMANSHIP
The Contractor shall determine the required frequency of testing and conduct sufficient tests on the sourced material for each type of material, in
order to ensure that the quality of materials produced will meet the specified requirements for the particular layer for which it will be used.
The Engineer shall carry out quality control testing and may, at his discretion, elect to use the Contractor’s test results if he is satisfied that the
Contractor’s process control requirements are acceptable for quality control purposes.
Any work or materials which do not comply with the specified requirements, shall be removed and replaced with work or materials which comply
with the requirements or, if the Engineer so agrees, shall be repaired so that it shall comply with the specified requirements after having been
repaired.

B3.1 DRAINS
CONTENTS
B3.1.1 SCOPE
B3.1.2 DEFINITIONS
B3.1.3 GENERAL
B3.1.5 MATERIALS

B3.1.8 WORKMANSHIP
B3.1.1 SCOPE
This Part covers additional specifications for work to enhance the labour component of construction activities, over and above labour employed
for conventional construction activities, where specified in Part A. This Section includes concrete mixed by hand and construction of banks and
dykes.
B3.1.2 DEFINITIONS
B3.1.3 GENERAL

B3.1.5 MATERIALS

None applicable unless specific specifications have been accepted as proposed by the Contractor or included to the Contract Documentation.

B3.1.7.1 Concrete mixing by hand
Concrete may be mixed by hand or in hand-turned concrete mixers for small pours up to one (1) cubic metre. Larger pours greater than one (1)
cubic metre shall be machine mixed with on-site mechanical mixers and/or batch plants.
strength so that, considering the expected variability of the concrete and test procedures, no more than 5 percent of strength tests will be expected
to fall below the specified characteristic compressive strength.
Concrete shall be hand-mixed on a prepared mixing floor of adequate area to facilitate proper mixing without contamination by any foreign
materials.
The sand shall be measured off, tipped onto the mixing floor and spread in a circle. The cement (one or two whole sacks, as required by the mix
design) shall then be spread evenly across the sand and mixed in with shovels, turning the mixture into the middle of the circle and out again.
When the colour is even, the mix shall be shaped with a hollow in the centre.

Part of the mixing water shall be poured into the hollow and mixed in. More water shall be slowly added and mixed in until all the water has been
added. The materials shall be turned into the middle of the circle and out again at least twice. The mix should be soft and even with no dry patches.
The mix shall then be spread in a circle.
The stone shall be measured off and spread evenly across the mortar and mixed with shovels, by turning the mixture into the middle and out again
at least twice. Concrete shall be properly mixed to a uniform consistency without fatty or harsh patches. The total period between the times that
the cement is placed into the mix until mixing starts shall not exceed 15 minutes.
The selection of mixing and batching locations shall be so chosen to minimise the transport of concrete placement.
B3.1.7.2 Classes of Excavation

intermediate for payment purposes in terms of Table B3.1.7-1 or, if the Contractor does not agree with the classification, in terms of Table
B3.1.7-2. The decision of the Engineer regarding the classification of the excavated materials shall then be final and binding, subject to the
provisions of the conditions of contract.
Materials
Description
Classification
Soft
hand-swung tool.
Intermediate
Consistency Number of DCP blows to penetrate 100 mm *1

Materials
Classification
Granular soil Cohesive soil Granular soil Cohesive soil *2
*1 Only applicable to materials comprising not more than 10 % gravel of size less than 10 mm and materials containing no cobbles or
B3.1.7.3 Banks and Dykes

Mitre banks, catchwater banks and dykes shall be constructed of approved soil or gravel obtained from open drain excavation or, if no suitable
material can be obtained from that source, from suitable approved alternative sources, and be placed in such a way that the water will flow on the
natural ground and against the bank, or inside an excavated drain and bank combination.
The banks and dykes shall be properly compacted to 93 % of MDD in layers not exceeding 150 mm.
If so specified, mitre banks facing shall be constructed of hand-packed stone pitching as detailed in Clause A11.1.7 of Chapter 11.
B3.1.8 WORKMANSHIP

C3.1 DRAINS
(i) Preamble
The tendered rate for each item shall include full compensation for providing, maintaining and decommissioning upon completion, of all the plant,
equipment, labour, tools, incidentals and supervision to carry out the activity or construct the works in the item, unless otherwise stated.
(ii) Notes on measurement and pay Items
1. Unless otherwise ordered or stated in the Contract Documentation, open drains, subsoil drains and trenches will be measured from the
surface of the ground along the centre-line of the trench to the bottom of the specified bedding layer (as applicable).
5. Where shoring is specified or ordered, the length of shoring measured for payment will be the length of the centre-line of the open drain or
trench.
shall include the cost thereof in other pay items as he deems appropriate:
pay items.
6. No separate payment will be made for the hauling of any materials where the material is moved over a distance of less than, and up to 1,0
km.
8. No separate payment will be made for the removal or any surplus material imported to complete the works.
9. For all Works performed, precautionary measures required in terms of the Occupational Health and Safety Act (Act 85 of 1993) and the latest
amendments thereof as well as the latest Construction Regulations shall be deemed included in the rates tendered for the relevant products.
The following items of work, when specified, shall be carried out, measured and paid for in accordance with the appropriate Sections of the
specifications.
C4.2.5 & C4.2.12 of Chapter 4
Open drain excavation A3.1.7.2
C5.1.2 & C5.2.9 of Chapter 5
C1.6 of Chapter 1 - All applicable
Clearing and grubbing A3.1.7.2; A3.1.7.3
items

(v) Items specifically for this Section of the specifications
C3.1.1 Excavation for open drains:
C3.1.1.1 Excavating all material situated within the following depth ranges below the surface level
using conventional methods:
(a) 0 m to 1,5 m cubic metre (m3)
(b) Exceeding 1,5 m and up to 3,0 m cubic metre (m3)
(c) Etc, in increments of 1,5 m cubic metre (m3)

C3.1.1.2 Extra over sub-item C3.1.1.1 for excavation in hard and boulder material, irrespective of cubic metre (m3)
depth
C3.1.1.3 Extra over sub-item C3.1.1.1 for excavation in stabilised existing road layers, irrespective of cubic metre (m3)
depth
C3.1.1.4 Excavating soft material situated 0 m to 1,5 m below the surface level using labour enhanced cubic metre (m3)
construction methods
C3.1.1.5 Excavating intermediate material situated 0 m to 1,5 m below the surface level using labour cubic metre (m3)
enhanced construction methods
The unit of measurement shall be the cubic metre of material excavated in accordance with the authorised dimensions, measured in place before
excavation. Only excavation for open drains as defined in Clause A3.1.7.2 shall be measured.
Irrespective of the total depth of the excavation, the quantity of material in each depth range shall be measured and paid for separately.
Excavations shall be done using conventional construction methods and/or labour enhanced construction methods as specified.
Payment made for either hard, boulder or stabilised existing road layers shall only be measured for the one applicable extra over category.
The tendered rates shall include full compensation for the excavation of the material to the required dimensions, lines, levels and grades, the
trimming of the open drain and the loading and disposal/utilisation of the material as directed, including haul of 1,0 km when using conventional
construction methods.
Loading and hauling, where applicable, including a haul of 1,0 km, shall be measured and paid under Section C1.7 of Chapter 1. Where the
excavation of material is specified by means of labour enhanced construction methods, the tendered rates shall include loading and transport by
wheelbarrow if the material is disposed of or utilised within a radius of 50 m, alternatively loading by hand onto transport vehicles for such disposal
or utilisation elsewhere, within a haul distance of 1,0 km.
For payment purposes a distinction shall be made between materials as classified according to Clause A3.1.7.1 under Classification of Materials.
C3.1.2 Clearing, shaping and disposal of accumulated sediment in existing unlined open
drains
C3.1.2.1 Using conventional methods cubic metre (m3)
C3.1.2.2 Using labour enhanced construction methods cubic metre (m3)

The unit of measurement shall be a cubic metre of sediment, including accumulated existing cut slope rubble and vegetation, removed measured
in place before removal. Where such measurement is impractical or impossible, as decided by the Engineer, quantity measurement shall be
determined as 70 % of volume measured in haulage vehicles.
Excavations shall be done using conventional construction methods and/or labour enhanced construction methods as specified.
The tendered rate shall include full compensation for excavating the material, protecting the existing drainage structures, trimming the floors and
sides of the open drains and loading and disposing of material as prescribed.
clearing and shaping of existing unlined open drains is specified by means of labour enhanced construction methods, the tendered rates shall
include loading and transport by wheelbarrow if the material is disposed of or utilised within a radius of 50 m, alternatively loading by hand onto
transport vehicles for such disposal or utilisation elsewhere, within a haul distance of 1,0 km.
The clearing of existing lined side drains will be measured and paid for under item C3.1.3.
C3.1.3 Excavation, clearing and disposal of accumulated sediment in existing lined drains and
drainage systems
C3.1.3.1 Using conventional methods (up to 1,5 m):
(a) Manholes and inlet and outlet structures cubic metre (m3)
(b) Culvert barrels cubic metre (m3)
(c) Concrete or other lined side drains cubic metre (m3)

C3.1.3.2 Using conventional methods (in excess of 1,5 m):
C3.1.3.3 Using labour enhanced construction methods:

The unit of measurement shall be the cubic metre of material excavated and removed, measured in place before excavation. Where such
measurement is impractical or impossible, as decided by the Engineer, quantity measurement shall be determined as 70 % of volume measured
in haulage vehicles.
Excavation for the clearing of existing lined drains and drainage systems up to a depth of 1,5 m shall be done using conventional construction
methods and/or labour enhanced construction methods as specified and measured. Excavation in excess of 1,5 m depth shall be paid for under
item C3.1.3.2.
The tendered rate shall include full compensation for excavating the material, protecting the existing linings or drainage systems, dealing with any
surface or subsurface water, and loading and disposing of the excavated material.
clearing of existing lined drains and drainage systems is specified by means of labour enhanced construction methods, the tendered rates shall
include loading and transport by wheelbarrow if the material is disposed of or utilised within a radius of 50 m, alternatively loading by hand onto
transport vehicles for such disposal or utilisation elsewhere, within a haul distance of 1,0 km.
C3.1.4 Excavation and disposal of material for subsoil drainage systems:
C3.1.4.1 Excavating in all material situated within the following depth ranges below the surface:

C3.1.4.2 Excavating soft material situated within 0 m to 1,5 m below the surface level using labour cubic metre (m3)
enhanced construction methods
C3.1.4.3 Excavating intermediate material situated within 0 m to 1,5 m below the surface level using cubic metre (m3)
labour enhanced construction methods
C3.1.4.4 Extra over sub-item C3.1.4.1 for excavation in hard and boulder material, irrespective of cubic metre (m3)
depth
C3.1.4.5 Extra over sub-item C3.1.4.1 for excavation through stabilised existing road layers cubic metre (m3
C3.1.4.6 Excavation and disposal of material for composite in-plane fin-drain type drainage systems
using a trenching machine:
(a) Trench width of …..and depth of....... metre (m)
(b) Etc for width of…..and depth of...... metre (m)

The unit of measurement for items C3.1.4.1 to C3.1.4.5 shall be the cubic metre of material excavated in accordance with the authorised
dimensions, measured in place before excavation. Irrespective of the total depth of the excavation, the quantity of material per classification in
each depth range shall be measured and paid for separately.
Excavations shall be done using conventional construction methods and/or labour enhanced construction methods as specified and measured.
The tendered rates shall include full compensation for the excavation of the material to the required dimensions, lines, levels and grades, all
temporary shoring and strutting, and the loading and disposing of the excavated material.
Loading and hauling, where applicable, including a haul of 1,0 km, shall be measured and paid under Section C1.7 of Chapter 1. For
payment purposes a distinction shall be made between materials as classified according to Clauses A3.1.7.1 and B3.1.7.2 under Classification of
Materials.
Item C3.1.4.6 for excavation for composite in-plane fin-drain type drainage systems using a trenching machine shall be to the required width and
depth indicated. The unit of measurement shall be the linear metre of trenching excavated. No distinction shall be made between soft material
and stabilised layers of existing road layers. Hard material shall not be required to be excavated by trenching machine.
Loading and hauling, where applicable, including a haul of 1,0 km, shall be measured and paid under Section C1.7 of Chapter 1. Where
excavation is specified by means of labour enhanced construction methods, the tendered rates shall include loading and transport by wheelbarrow
if the material is disposed of or utilised within a radius of 50 m, alternatively loading by hand onto transport vehicles for such disposal or utilisation

elsewhere, within a haul distance of 1,0 km.
Where subsoil drainage systems are adjacent to structures such as culverts, that part of the excavation for subsoil drainage systems, which can
be made by widening the excavation for the structure, shall only be measured and paid for under excavation for such structure, and not under
excavation for the subsoil drainage systems.
C3.1.5 Impermeable backfilling to subsoil drainage systems
C3.1.5.1 Un-stabilised natural gravel obtained from approved sources on the site cubic metre (m3)
C3.1.5.2 G5 material obtained from commercial sources cubic metre (m3)
C3.1.5.3 Extra over items C3.1.5.1 and C3.1.5.2 for stabilisation with 4,0 % CEM II (32.5) cement cubic metre (m3)
The unit of measurement shall be the cubic metre of completed backfill, measured in place in the subsoil drainage systems and shall be calculated
in accordance with the authorised dimensions.
The tendered rate for item C3.1.5.1 shall include full compensation for procuring, furnishing, placing and compacting the backfilling.
Loading and hauling, where applicable, including a haul of 1,0 km, shall be measured and paid under Section C1.7 of Chapter 1.
The tendered rate for item C3.1.5.2 shall include full compensation for procuring, furnishing and transporting G5 material from commercial
suppliers, including the cost of transporting the material to the site irrespective of haul distance, and placing the materials as specified.
The tendered extra over rate for item C3.1.5.3 shall include full compensation for all additional costs for procuring, furnishing, mixing and placing
the cement stabilised backfill.
C3.1.6 Construction of banks and dykes:
C3.1.6.1 Banks and dykes using conventional methods cubic metre (m3)
C3.1.6.2 Banks and dykes using labour enhanced construction methods cubic metre (m3)
The unit of measurement shall be the cubic metre of material, measured in place in the banks or dykes, and calculated in accordance with the
authorised dimensions. Where open drain with bank/dyke combinations are constructed, excavation shall be measured and paid under item
C3.1.1.
The tendered rate shall include full compensation for procuring, furnishing, placing, watering, compacting, shaping and trimming the material in
the banks and dykes.
Loading and hauling, where applicable, including a haul of 1,0 km, shall be measured and paid under Section C1.7 of Chapter 1. Where
excavation is specified by means of labour enhanced construction methods, the tendered rates shall include loading and transport by wheelbarrow
if the material is disposed of or utilised within a radius of 50 m, alternatively loading by hand onto transport vehicles for such disposal or utilisation
elsewhere, within a haul distance of 1,0 km.
C3.1.7 Natural permeable material in subsoil drainage systems (approved crushed stone):
C3.1.7.1 Crushed stone obtained from approved sources on the site (state grade and size) cubic metre (m3)
C3.1.7.2 Crushed stone obtained from commercial sources (state grade) cubic metre (m3)
The unit of measurement for item C3.1.7.1 shall be the cubic metre of approved crushed stone in place in the drains, calculated in accordance
with the authorised dimensions. The volume occupied by the pipes shall be deducted when calculating the volume of the natural permeable
material.
The tendered rate shall include full compensation for procuring, furnishing and placing the material as specified.
For payment purposes a distinction shall be made between the different grades of approved crushed stone.
The unit of measurement for item C3.1.7.2 shall be the cubic metre of crushed stone in place in the drains, calculated in accordance with the
authorised dimensions. The volume occupied by the pipes shall be deducted when calculating the volume of the natural permeable material.
The tendered rate shall include full compensation for procuring, furnishing and transporting approved crushed stone from commercial suppliers,
including the cost of transporting the material to the site irrespective of haul distance, and placing the materials as specified.
For payment purposes a distinction shall be made between the different grades of approved crushed stone.
C3.1.8 Natural permeable material in subsoil drainage systems (approved natural sand):
C3.1.8.1 Natural sand obtained from approved sources (state grade & source) cubic metre (m3)
C3.1.8.2 Natural sand from commercial sources (state grade) cubic metre (m3)

The unit of measurement for item C3.1.8.1 shall be the cubic metre of approved sand in place in the drains, calculated in accordance with the
authorised dimensions. The volume occupied by the pipes shall be deducted when calculating the volume of the permeable material.
The tendered rate shall include full compensation for procuring, furnishing and placing the sand as specified.
For payment purposes a distinction shall be made between the different grades of sand.
The unit of measurement for item C3.1.8.2 shall be the cubic metre of sand in place in the drains, calculated in accordance with the authorised
dimensions. The volume occupied by the pipes shall be deducted when calculating the volume of the permeable material.
The tendered rate shall include full compensation for procuring, furnishing and transporting approved sand from commercial suppliers, including
the cost of transporting the material to the site irrespective of distance, and placing the material as specified.
For payment purposes a distinction shall be made between the different grades of sand.
C3.1.9 Pipes in subsoil drainage systems:
C3.1.9.1 U-PVC pipes and fittings, normal duty, complete with couplings (state size and whether or metre (m)
not perforated or slotted)
The unit of measurement for pipes shall be the metre of pipe, measured in place along its centreline, including the length of fittings.
The tendered rate shall include full compensation for procuring, furnishing, laying and jointing the pipes and fittings as specified.
C3.1.10 Polymer film sheeting or similar approved material, for lining subsoil drainage
systems:
C3.1.10.1 0,15 mm thick square metre (m²)
C3.1.10.2 0,25 mm thick square metre (m²)
The unit of measurement shall be the square metre of polymer film sheeting installed, measured net from the specified dimensions.
The tendered rate shall include full compensation for procuring, supplying, cutting, overlapping, jointing, placing and protecting the sheeting as
specified, as well as for wastage.
C3.1.11 Geotextiles (indicate type, grade, etc.) square metre (m2)
The unit of measurement shall be the square metre of geotextile supplied and installed as specified in Section A12.11 of Chapter 12.
The tendered rate shall include full compensation for furnishing, procuring, cutting, overlapping, jointing, placing and protecting the geotextile as
specified, as well as for wastage.
C3.1.12 Composite drainage systems
C3.1.12.1 In-plane drainage systems (state size, type of core and type grade, etc. of geotextile) metre (m)
C3.1.12.2 Vertical subsoil strip drainage systems (state size, type of core and type grade, etc. of metre (m)
geotextile)
C3.1.12.3 Panel drainage systems (state size, type of core and type grade, etc. of geotextile) metre (m)
C3.1.12.4 Alternative drainage systems as detailed in Contract Documentation (state size, type and metre (m)
other details)
The unit of measurement shall be the metre of composite or alternative drainage system as specified, measured in place along the centre line of
the system.
The tendered rate shall include full compensation for procuring, furnishing, assembling, installing and jointing the composite or alternative drainage
system, including perforated or other types of drainage core, complete as specified.
C3.1.13 Concrete outlet structures, manhole boxes, junction boxes and cleaning eyes for
subsoil drainage systems:
C3.1.13.1 Outlet structures (specify each type and drawing reference) number (No)
C3.1.13.2 Inspection boxes (specify each type and drawing reference) number (No)
C3.1.13.3 Junction boxes (specify each type and drawing reference) number (No)

C3.1.13.4 Cleaning eyes (specify each type and drawing reference) number (No)
The unit of measurement shall be the number of outlet structures, manhole boxes, junction boxes and cleaning eyes for subsoil drainage systems
constructed in accordance with the details on the drawings and the Engineer’s instructions.
The tendered rates shall include full compensation for all excavation, backfilling, compacting to 93 % of MDD, disposing of surplus excavated
material, keeping the excavations safe, dealing with any surface or subsurface water, procuring and furnishing all materials, providing, erecting
and removing formwork, mixing, transporting, placing and curing the concrete, and all labour and constructional plant required for constructing the
concrete outlet structures, subsoil drain inspection boxes, subsoil junction boxes and cleaning eyes, complete as specified.
The tendered rate shall also include full compensation for procuring and finishing the galvanised woven wire mesh, cutting, waste, installing the
wire mesh at outlets and keeping the wire mesh in the pipe openings clean for the duration of the contract period.
C3.1.14 Caps for subsoil drain pipes:
C3.1.14.1 Concrete caps number (No)
C3.1.14.2 Cast metal iron caps number (No)
C3.1.14.3 Other (Glass fibre reinforced, PVC etc.) (specify) number (No)
The unit of measurement shall be the number of caps supplied as specified, and the tendered rate shall include full compensation for supplying
and installing the caps.
C3.1.15 Repairing or replacing existing drainage systems Provisional sum

The provisional sum given for repairing or replacing existing drainage systems shall be expended in terms of the general conditions of contract,
for unmeasured work to be undertaken as described in the Contract Documentation.
C3.1.16 Loading and hauling of material in excess of 1,0 km cubic metre-kilometre (m3-km)
The measurement and payment for hauling material referred to in items C3.1.1, C3.1.2, C3.1.3, C3.1.4, C3.1.5, C3.1.6, C3.1.7, C3.1.8, C3.1.17
and C3.1.18, if any, shall be in accordance with Section C1.7 of Chapter 1.
C3.1.17 Backfilling existing eroded side drains cubic metre (m3)
The unit of measurement shall be the cubic metre of approved granular material placed and compacted to 93 % of MDD, measured in place after
compaction. Where such measurement is impractical or impossible, as decided by the Engineer, quantity measurement shall be determined as
70 % of the loose volume of imported material.
The tendered rate shall include full compensation for procuring, furnishing, transporting, placing and compacting the granular material and
including haul of 1,0 km. Where trimming or benching of the side drains and disposal of resulting material is required, it shall be measured and
paid under item C3.1.3.

C3.1.18 Backfilling of drains with selected material compacted to 93 % of MDD prior to cubic metre (m3)
construction of concrete lining and/or stone pitched lining
The unit of measurement shall be the cubic metre of compacted material and the quantity shall be calculated from the authorised dimensions
given on the drawings or as specified by the Engineer.
The tendered rate shall include full compensation for procuring, as if from soft excavation or borrowpits, breaking down, placing and compacting
the material in 150 mm layers, transporting of the material transport over a haul of 1,0 km as well as for shaping the top surface in accordance
with the drawings.
C3.1.19 Exposing of existing subsoil drains cubic metre (m3)
The unit of measurement shall be the cubic metre of material removed to expose the drain for the purposes of refurbishment existing drains. This
item shall not be applicable in cases where complete substitution or replacement of existing drains is specified.
The tendered rate shall include full compensation for all labour and tools required for removing the material. The re-instatement of the drain
elements, as may be specified, shall be paid for under the relevant items for constructing a new drain.
C3.1.20 Breaking into existing drainage structures and install subsoil drain pipe number (No)
The unit of measurement shall be the number of subsoil drain pipes built into existing drainage structures in accordance with the details on the
drawings or as specified by the Engineer.

The tendered rates shall include full compensation for supplying all labour, constructional plant and materials required, for all excavation, breaking
into existing drainage structures, building pipes into the newly formed accesses, sealing around the pipes and making the joints watertight,
breaking out existing benching and channeling where required and reconstructing them complete with granolithic rendering to suit the new pipe
arrangement, backfilling and compacting to 93 % of MDD, transporting (including all haulage) and disposing of all surplus excavated material and
debris to approved dumping sites provided by the Contractor, and dealing with the flows in the existing structures.
No distinction will be made between different types of structures, or diameters of subsoil drain pipes.
C3.1.21 Clearing of existing subsoil drains
C3.1.21.1 Cleaning rod, brush and flushing metre (m)
C3.1.21.2 Hydro jetting metre (m)
The unit of measurement for clearing of existing subsoil drains shall be the metre of drain cleared with a sewer cleaning rod and brush, thorough
flushing and mandrill testing.
The unit of measurement for hydro jetting will include the establishment on site, hydro jetting and vacuuming of specified drains at various locations
on site.
The tendered rate shall include full compensation for all labour, equipment, tools, water and transport required for clearing existing subsoil drains
and for disposal of the cleared material to approved sites.
C3.1.22 Test flushing of subsoil drain pipe systems number (No)
The unit of measurement shall be the number of tests satisfactorily completed on newly installed or unblocked sections of drain system, irrespective
of its length. No payment will be made for tests, which have to be repeated due to blocked pipes or faulty workmanship.
The tendered rate shall include full compensation for the provision of a water tanker, water, equipment and labour necessary to carry out the tests,
complete as specified.
C3.1.23 Subsoil drain outlet marker (type or drawing specified) number (No)
The unit of measurement is the number of subsoil outlet markers installed in accordance with the details on the drawings.
The tendered rate shall include full compensation for procuring and furnishing the subsoil drain outlet marker and installation in accordance with
the details on the drawing.
C3.1.24 Submission of as built drawings by the Contractor Provisional sum
The provisional sum given for the Contractor to provide the Engineer with as built drawings pertaining to all subsoil drains on the site. The drawings
must contain the location, co-ordinates of in- and outlets, length and depth and must be provided to the Engineer prior to the site hand over.

D3.1 DRAINS
PART D: GUARANTEES & COMPLIANCE CERTIFICATES
CONTENTS
D3.1.1 SCOPE
D3.1.2 GENERAL

3.2 CULVERTS
CONTENTS
A3.2.1 SCOPE
A3.2.2 DEFINITIONS
A3.2.3 GENERAL
A3.2.5 MATERIALS
A3.2.8 WORKMANSHIP

PART C: MEASUREMENTS AND PAYMENTS
A3.2 CULVERTS
A3.2.1 SCOPE
Drainage under this Section covers mainly culverts and conduits and their associated works in water courses or from natural or shaped areas, but
may also cover drainage of road or bridge surfaces. This Section covers work in connection with the construction of in situ constructed and
prefabricated culverts and other closed conduits to provide such drainage, together with inlet and outlet structures, manholes and other
appurtenant structures. Different Road Authorities may differentiate between minor culverts, lesser culverts or major culverts. Major culverts are
covered in Chapters 13 and 14.
The replacing and/or lengthening of existing culverts, modification of and repairs to existing drainage structures and catch pits as well as sleeving
or lining, partly of fully, of the insides of existing culverts are also included in this Section.
A3.2.2 DEFINITIONS
Culvert: is a structure other than a bridge which provides an opening under the carriageway or median for drainage or other purposes.
Major Culvert: is a cellular structure with dimensions less than those defining a bridge but with any clear span length (as measured horizontally
at the soffit perpendicular to the faces of its supports) equal to or larger than 2,1 m, or diameter equal to or larger than 2,1 m, or a culvert with a
total cross-sectional opening equal to or larger than 5,0 m2. (TMH19)
Minor Culvert: all culverts smaller than that defined as a Major Culvert are classified as lesser culverts. (TMH19)
A3.2.3 GENERAL
The attention of the Contractor is drawn to the requirement that information given on the drawings, longitudinal sections or drainage schedules
may have to be verified and reviewed to suit actual site conditions and therefore the Contractor shall only construct these culverts after the
Engineer has amended or verified the information on the drawings based on detail surveys taken on site.
Prefabricated units shall be ordered by the Contractor from actual measurements of lengths determined on site and not from lengths stated in the
drainage schedules or from the schedule of quantities.
All existing stormwater culverts, which are to be extended, shall be inspected on site and any defects reported to the Engineer prior to extensions
being constructed. Likewise, existing and new culverts are to be inspected for possible damage after completion of layerworks over the culverts.
A3.2.3.1 Types of culverts

For the purposes of this specification, the term "culverts" shall mean culverts constructed from-
a) Reinforced concrete floors and roofs and reinforced concrete walls, hereinafter referred to as "rectangular concrete culverts”. The reinforced
concrete floors and/or roofs may be either cast in situ or prefabricated units constructed elsewhere;
b) Reinforced concrete floors and roofs and reinforced brickwork walls, hereinafter referred to as "rectangular brickwork culverts”. The reinforced
concrete floors and/or roofs may be either cast in situ or prefabricated units constructed elsewhere;
c) Prefabricated reinforced concrete pipes with circular sections, hereinafter referred to as "concrete pipe culverts";

d) Prefabricated reinforced concrete culverts other than pipe culverts hereinafter referred to as "prefabricated portal culverts", generally of
combined wall and roof prefabrication. The reinforced floors may be either cast in situ or prefabricated units constructed elsewhere. These
culverts are generally of rectangular construction;
e) Prefabricated corrugated metal pipes and pipe arches, hereinafter referred to as "metal culverts".
f) U-PVC pipes with circular section, hereinafter referred to as “U-PVC culverts”
g) Other types of culverts not included above, if required, shall be specified in the Contract Documentation.

A3.2.5 MATERIALS
The material specifications are the required specifications for the materials as placed and/or processed in its final position.
It is the Contractor’s responsibility to ensure that the materials delivered to the site shall meet these specified requirements.
Prior to the manufacture of any prefabricated units by the Contractor’s manufacturer, the manufacturer shall submit his Quality Plan to the Engineer
to verify that all prefabricated units will be manufactured in full compliance with the relevant SANS requirements. No prefabricated units shall be
ordered until the Engineer has satisfied himself that the proposed units have been or will be manufactured to the required specifications and
tolerances as well as the load bearing requirements. In particular the manufacturer shall check each prefabricated portal culvert unit for steel cover
compliance, and random checking of units shall not be accepted. The Engineer’s representative may visit the factory at any stage to ascertain
adherence to the quality plan. Should the manufacturer fail to adhere to their Quality Plan the Engineer may exercise the right to reject the use of
products from the manufacturer concerned. No claim from the Contractor for any resultant cost or delay due to such rejection, and due to
procurement from a new manufacturer, shall be entertained.
A3.2.5.2 Culvert materials

a) In situ concrete
All concrete work shall be carried out in accordance with the requirements of Section A13.4 of Chapter 13 of these specifications, read together
with the provisions of Clause A3.1.5.4.
b) Prefabricated portal culverts and prefabricated in/outlet, floor and roof slabs units
The prefabricated units shall comply with the requirements of SANS 986.
For durability requirements, all durability testing shall be done in accordance with Clause A20.1.5 for testing and Clause A20.1.7 for assessment
in Chapter 20 and shall fall within the severe category. For units within the 5,0 km zone from the coast the very severe category shall be used and
increased cover shall be as specified by the Engineer.
Portal and rectangular prefabricated units shall be transported and handled with sufficient care to prevent stressing, cracking or damage to the
unrestrained elements of the units. Cracks or damage shall constitute adequate reason for rejection by the Engineer or required confirmation by
the manufacturer of their serviceability.
All broken, bent, chipped, cracked, dented, corroded or otherwise damaged or substandard units shall be repaired to the Engineer's specification
or, where this is not acceptable or does not comply to the SANS specification, they shall be removed and replaced with undamaged units, at the
Contractor’s cost.
Slab units which are thinner than the specified thickness, or which may exhibit signs of substandard work shall be removed and replaced with
units which conform to the specifications.
c) Prefabricated concrete pipe culvert units
Prefabricated concrete pipe culvert units shall comply with the requirements of SANS 677. Pipes with ogee joints shall be provided, unless
otherwise specified.
All broken, bent, chipped, cracked, dented, corroded or otherwise damaged or substandard units shall be repaired to the Engineer's specification
or, where this is not acceptable or does not comply with the relevant SANS specification, they shall be removed and replaced with undamaged
units, at the Contractor’s cost.
d) Brickwork
Bricks shall be engineering bricks conforming to the requirements of SANS 227. Bricks may be manufactured on site or elsewhere.
The limit for water absorption in the 24 hour immersion test shall be 8 % maximum.
All bricks shall be unbroken, except where required as closers.
e) Plaster
Plaster shall consist of one part of CEM I class 32.5 cement to four parts of approved fine sand, and shall conform to the requirements of SANS
2001.
f) Manhole covers, grid inlets, frames, etc.
Manhole covers and frames, grid inlets and accessories of metal, or non metal composition shall be supplied and/or manufactured in accordance
with the details shown on the drawings and be of the size and type indicated. Frames, grid inlets and covers which are of project specific

requirements shall be manufactured and installed as indicated on the drawings, and all steel elements shall be galvanised in accordance with
SANS 121. Frames, grids/gratings covers and accessories of cast iron, synthetic or composite materials shall comply with the requirements of
SANS 558, SANS 1115, or SANS 50124 and be of the strength class, size and type specified,
Before fixing cast iron manhole covers and frames, they shall be dipped in an approved preservative and gratings and frames painted with two
coats of bituminous paint.
g) Corrugated metal culvert units
Corrugated metal culverts shall either be supplied fully assembled; or as unassembled nestable arch or circular segments, in which case they
shall be assembled in accordance with the manufacturers specifications. The manufacturer’s specifications shall be provided to the Engineer prior
to the start of any assembly.
Metal culverts shall be supplied with inlet and outlet ends finished by one of the following two methods, whichever is shown on the drawings or
has been specified:
Where no concrete inlet and outlet structures but only beveled pipe ends are required, inlet and outlet units shall be beveled to suit the skew angle
of the culverts and the side slope of the fill and pavement. Such beveled units shall be machined and shall receive full corrosion protection
treatment after such machining.
Where in situ concrete inlet and outlet structures are required, the ends of the culvert units shall be cut to the required plan skew angle (if any)
and provided with anchor bolts projecting radially around the edge as shown on the drawings for bonding the metal culvert into the concrete inlet
and outlet structures.
The Contractor shall not store any nestable culvert units on the site in such a manner that moisture can accumulate between the contact faces of
the nested units, as this may adversely affect the spelter coating and render the units liable to rejection. Any units damaged by corrosion shall, if
not rejected, be repaired by cleaning all affected areas and applying at least two coats of an approved zinc-rich epoxy primer which complies with
the requirements of SANS 926, in accordance with the manufacturer's instructions, or as directed by the Engineer.
Uneven joints, distorted shapes, deviations from a straight centre line, irregular or diagonally ruptured sides, loose rivets, rivets not in line or
irregularly spaced, poorly finished rivet heads, illegible trade marks, or a lack of rigidity.
h) Protective coating for metal culverts
Metal culverts shall have a protection coating as specified in the Contract Documentation or indicated on the drawings, and may be of galvanized,
aluminized or polymer coatings to the specified thickness. Where soil or water conditions are likely to cause excessive corrosion of metal culverts,
the Engineer may prescribe that prefabricated units be protected by the application of a mastic asphalt protective coating. The coating shall be
applied to either the inside, the outside or to both sides of the metal culvert units as may be directed by the Engineer.
The mastic asphalt shall contain fibres and filler and shall be supplied as a spray or brush-grade material as prescribed.
The surfaces to be protected shall be cleaned to remove all moisture, dirt, all, paint, grease, alkalis, rust, mill scale or other deleterious matter.
The material shall be thoroughly mixed until all fibres and filler are uniformly distributed.
Spray-grade mastic shall be applied by means of an airless gun and shall be of a suitable consistency without the addition of a harmful amount of
thinners.
Brush-grade mastic shall be applied with an ordinary roofing brush, with the second coat being applied at right angles to the first coat.
The final film thickness measured on the crest of corrugations shall be a minimum of 1,3 mm or such other thickness as may be specified.
Care shall be taken not to damage the protective coating, and all damage to the coating shall be repaired before the culvert is put to use.
i) U-PVC culverts
U-PVC culverts shall comply to the requirements of SANS 791 for solid wall pipes (category-heavy duty), and shall have socketed ends should
joining be required.
j) Alternative culvert materials
Alternate culvert materials, if any, shall be specified and detailed in the Contract Documentation.
A3.2.5.3 Skewed ends

Where culverts are to be constructed at a skew angle, the prefabricated culvert units at the inlet and outlet of the culvert shall be supplied with
skew ends by the manufacturer, if required. The cutting of skew ends on the site shall not be allowed.
Prefabricated portal and rectangular culverts placed on a skew shall be constructed with cast in-situ skewed ends as shown on the drawings. In-
situ skew ends are to be constructed simultaneously with the wingwalls and headwalls.
A3.2.5.4 Prefabricated energy dissipaters in outlet structures

Where shown on the drawings, the Contractor shall supply and install in the outlet structures, prefabricated reinforced concrete energy dissipaters
of class C25/30-20 concrete with dimensions as shown on the drawings. All concrete work shall comply with the requirements of Section A13.4
of Chapter 13.
A3.2.5.5 Fine granular material

Wherever the use of fine granular material is specified in this section for the bedding of the prefabricated concrete floor slabs of the culverts, it
shall mean sand or other cohesionless material, all of which shall pass through a 7,0 mm sieve and not more than 10 % of which shall pass
through a 0,15 mm sieve.
A3.2.5.6 Materials at joints

Joint filler and joint sealing material shall comply with the requirements of Section A13.7 of Chapter 13.

The Contractor shall submit his plant and equipment list for excavating, stockpiling if specified, loading and hauling and compaction, erection and
installation, as part of his method statement to perform the different elements of the drainage works specified in Section A3.2.

A3.2.7.1 Construction methods
Where clearing and/or grubbing and the removal of trees is specified by the Engineer, it shall be executed as specified in Section A1.6 of Chapter
1.
Prefabricated culverts shall be installed by either -
The "trench method", where the units are laid in a trench excavated below the existing ground level or in a trench excavated in constructed
subgrade and, if necessary, subbase layers, or, in the case of an existing road, in a trench excavated through all road layers;
or
The "embankment method", where the units are laid approximately on the existing ground surface or on a prepared bedding and the subgrade is
then constructed on either side and over the culvert.
If lengthening of existing culverts are specified such lengthening shall generally be according to the "embankment method". The Contractor shall at all
times ensure that the existing drainage is at all times maintained and any damage caused as a result of blocked culverts during construction shall be
repaired at the Contractor's cost.
All new prefabricated culverts/portals shall be installed by the “trench method”, unless specified otherwise by the Engineer.
The bottom of the excavation for culverts that are to be replaced or lengthened shall be inspected by the Engineer prior to the placing of the bedding
material.
Where the material is found to be unsuitable, it shall be removed to a depth specified by the Engineer and then replaced with selected material
compacted to at least 93 % MDD in layers not exceeding 150 mm thickness.
Design invert levels of drainage culverts shall be verified on site by the Engineer with the assistance of the Contractor before installation of new or
lengthened culverts may commence.
In all cases where soft founding material is classified as suitable for bedding construction, the in-situ material shall be scarified, moistened and
compacted to a depth of 150 mm below founding level to 90 % or 93 % MDD, as specified by the Engineer. The depth of preparation and compaction
of founding material shall be as indicated on the drawings or as specified by the Engineer.
The larger sizes of portal or rectangular culverts shall normally be constructed by the embankment method.
Surface drainage shall be controlled by the construction of temporary earth berms and drainage diversion channels.
The Contractor shall strictly comply with all the appropriate statutory safety provisions in regard to trench excavations.
A3.2.7.2 Excavation for construction by trench method

a) Classification of Materials
All excavation classification of materials in this Section shall be as specified in Clause A3.1.7.1.
b) Excavation
All excavations for culverts shall be excavated in the position and to the required dimensions. Overbreak in width or depth, unless specified by
the Engineer, shall be in filled by the Contractor and shall not be measurable for payment.
In the case of culverts to be constructed by the trench method, the Contractor shall first construct the fill, subgrade and, if necessary, the subbase
to such level as will provide a minimum cover, above the proposed level of the top of the culvert. Road base layers shall not be constructed before
the culvert and backfill have been completed. Before trench excavation may commence, the minimum height of fill construction over the top of a
proposed concrete culvert shall be 100 mm or such greater height as may be indicated on the drawings, whichever is the greater for metal culverts,
this minimum height shall be 0,25 times the diameter of the pipes, or 0,25 times the span of pipe arches. The Contractor may then commence
excavating the trench for the culvert from the downstream end. Excavation less than 1,5 m deep shall be done either by using labour enhanced
construction methods or by using conventional construction methods, as specified and measured in the schedule of quantities. Excavations shall
be continuously monitored and assessed for stability and safety and if any risk of instability is evident the Contractor shall not proceed with culvert
excavation until safe working conditions have been re-established. The Engineer should be informed of all the actions taken in this regard.
The amount by which the excavation is to exceed the proposed level of the invert of the culvert shall be sufficient to allow the type and thickness
of bedding material to be placed as specified or as indicated on the drawings.
The minimum amount by which the excavation shall be deeper than the proposed level of the bottom of the culvert floor slab shall be 75 mm in
the case of culverts with prefabricated invert slabs. In the case of culverts with cast in situ invert slabs, the excavation shall exactly accommodate
the floor slab.
Notwithstanding the above, the base layer shall not be constructed before the culvert and the backfill have been completed.
c) Width of excavation
The width of excavations shall be sufficient to allow the bedding, proper construction and backfilling of culverts. The width of the excavation for
each size of culvert shall be as shown on the drawings or as may be prescribed by the Engineer in writing.

d) Excavation by hand
Where the circumstances prevent the use of mechanical excavators due to possible damage to existing works and soft material can only be
removed by hand tools, the Engineer shall authorise the excavation by hand should he be satisfied that the Contractor had been unable to prevent
the necessity for excavation by hand by proper planning and precautionary measures. Payment for this hand excavation shall be made under
excavation using labour enhanced construction methods in terms of B3.2.7.2.
e) Drainage of excavations
The Contractor shall, in terms of Clause A1.2.3.19 of Chapter 1, apply suitable, effective drainage and dewatering methods for preventing the
ingress of water into the excavation and to keep them dry.
Drainage methods, with the exception of pumping, shall be maintained until the backfilling has been completed. Between various construction
stages, pumping may be interrupted in consultation with the Engineer.
Any draining or pumping of water shall be done in a manner to preclude the concrete or materials or any part thereof from being eroded.
A3.2.7.3 Preparation for construction by the embankment method

Where culverts are to be constructed by the embankment method as defined in Clause A3.2.7.1 the Contractor shall level the existing ground by
excavating, filling and compacting as may be necessary so as to provide exactly the required slope and a uniform density over the entire length
of the culvert. Where excavation is required for the founding of culverts, such excavation shall be done in accordance with Clause A3.2.7.2.
The finished level of the ground for the bedding of the culvert shall be not lower than 75 mm in the case of culverts with prefabricated invert slabs.
In the case of culverts with cast in situ invert slabs, the level shall exactly accommodate the floor slab.
A3.2.7.4 Unsuitable founding conditions

Where the bottom of the trench does not provide a suitably firm foundation for the culvert on account of soft, unstable, or otherwise unsuitable
material being encountered, the unsuitable material shall be excavated to a depth below the bottom of the culvert as may be indicated by the
Engineer. The Contractor shall excavate the unsuitable material to the depth indicated and shall replace it with an approved material properly
compacted to provide a firm foundation layer.
The width of the excavation and foundation later shall be as prescribed by the Engineer, but in the case of culverts to be constructed by the
embankment method, the width shall be wider by at least one culvert diameter on each side of the culvert or set of culverts.
Other special construction methods may be shown on the drawings or specified in the Contract Documentation in specific cases.
A3.2.7.5 Disposal of excavated material

Where excavated material does not comply with the requirements for backfilling material as specified hereinafter or is surplus to backfilling
requirements, such excavated material shall be removed from the site and disposed of in approved spoil areas or at such other places as directed
by the Engineer.
Material suitable for use in the works, however, shall be used as prescribed by the Engineer.
Payment for such material will be made as for excavation under item C3.2.1, and also under the appropriate item for such part of the works as
may be constructed from such material.
All excavated material shall be subject to the load and haul provisions specified in Section A1.7 of Chapter 1.
A3.2.7.6 Construction of culverts

a) General requirements
The construction of culverts shall be commenced at one end of the culvert, the position of which shall be fixed as shown on the drawings or as
prescribed by the Engineer.
Units which have been deformed or cracked, or which are not constructed to the required lines, levels and grades, or which become displaced in
the process of the work or during the contract period, shall be removed and replaced by the Contractor at his own cost.
Prefabricated slabs shall be lifted and handled by means of approved lifting devices only. During such procedures all relevant safety regulations
shall be adhered to. Lifting eyes shall be caulked with a suitable mortar after the units have been installed. All lifting holes shall be filled with
cement mortar and covered with class 3 geotextile.
The Contractor shall exercise due care not to damage, overstress or displace any culvert or prefabricated slab with his own traffic or compaction
equipment. Where loads exceeding those prescribed in the appropriate statutory provisions are likely to pass over completed culverts, the
Contractor shall provide additional cover over the culverts so as to ensure that the design stresses on the culverts will not be exceeded.
All concrete work shall be carried out in accordance with the provisions of Section A13.4 of Chapter 13 of these specifications.
b) Rectangular concrete and brickwork culverts
(i) Cast in situ floor slabs
Cast in situ floor slabs shall be constructed to the dimensions and at the locations as shown on the drawings or as may be
prescribed by the Engineer. They shall be reinforced with steel reinforcement as detailed on the drawings. Joints of the types
detailed on the drawings shall be formed in the floor slabs, as well as between the floor slabs and the inlet and outlet structures.
Where specified by the Engineer a screed layer shall be cast to the specified dimensions and details, prior to casting the floor slab.
In addition, longitudinal construction joints as shown on the drawings between the invert slabs of each the barrels of multiple
culverts are required. Allowance for Class F1 surface finish and soft board in these joints is made in the schedule of quantities. No
payment shall be made for formwork on the outside edges of invert slabs (closest to the excavated face).
(ii) Prefabricated floor slabs
A layer of fine-grained material at least 75 mm thick shall be placed on the bottom of the excavation or backfilled bedding, leveled,
compacted and trimmed to line and grade, to form a bed to receive the prefabricated slabs.

The slabs shall be carefully placed on the prepared bed, true to line and grade, and so bedded that they will be uniformly supported
over their whole area on the bedding.
(iii) Concrete walls for concrete culverts
Cast in situ concrete walls shall be constructed to the dimensions and at the locations as shown on the drawings or as may be
detailed on the drawings shall be formed in the walls, and between the wall and the inlet and outlet structures.
(iv) Brickwork walls for brickwork culverts
Culvert walls constructed from engineering bricks shall be to the dimensions as shown on the drawings or as may be prescribed
by the Engineer. Brickwork may be reinforced with steel or wire reinforcement, if and as detailed on the drawings.
Brickwork shall be built in English bond in a mortar consisting of one part of CEM I class 32.5 cement and six parts of sand, or in
stretcher bond where its thickness does not exceed 115 mm. It shall be well and regularly bonded without any false headers. All
engineering bricks shall be unbroken, except where required as closers. Engineering bricks shall be well wetted before laying and
each brick shall be pressed into its bed so as to leave a finished joint not exceeding 10 mm in thickness. All joints shall be filled
solid with mortar, and joints for exposed faces shall be pointed as the work proceeds.
Where pipes enter brickwork, such pipes shall be thoroughly caulked into the wall and rendered with mortar.
(v) Plaster for brickwork culverts
Where the plastering of brickwork is required, all joints shall be well raked out and the brick face thoroughly wetted before plaster
is applied. Plaster shall not be less than 12 mm or more than 20 mm thick. Plaster finish shall be smooth and even and shall not
show any trowel marks. Unless otherwise specified, all plaster shall be finished with a steel trowel.
Plaster shall be cured for at least 48 hours, where after installation of roof slabs may commence.
(vi) Cast in situ roof slabs
Cast in situ roof slabs shall be constructed to the dimensions and at the locations as shown on the drawings or as may be prescribed
by the Engineer. They shall be reinforced with steel reinforcement as detailed on the drawings. Joints of the types detailed on the
drawings shall be formed in the roof slabs, coinciding with similar joints in the floor slabs, and between the roof slabs and the inlet
and outlet structures.
(vii) Prefabricated roof slabs
The prefabricated concrete roof slabs shall be placed accurately and symmetrically on the concrete walls, with a thin layer of mortar
of one part of CEM I class 32.5 cement and six parts of sand between the contact surfaces to ensure a firm and uniform support.
The units shall be butted end to end with butt joints, which joints shall be covered with two layers of grade 3 geotextile as specified
in Section A12.11 of Chapter 12, pre-impregnated with a bituminous emulsion, or a similar approved material. The strip of geotextile
shall be at least 150 mm wide and placed symmetrically over the joint. The units shall first be treated with a primer of 60 % bitumen
emulsion over the width of the strip of geotextile.
Where two or more roof slabs are placed side by side to form a multi-barrel culvert, the space between the slabs, if any, shall be
filled with concrete up to the level of the top of the slab. Alternatively, such joints shall be sealed as for butt joints.
A3.2.7.7 Laying and bedding of prefabricated culverts

a) Concrete pipe culverts
Prefabricated concrete pipe culverts shall be laid on Class A, B, C or D bedding as shown on the drawings or as specified. The pipe ends shall
be laid hard up against each other so as to obtain tight joints. Ogee pipes shall be laid with their spigot ends pointing downstream. The joints shall
be sealed on the outside with two layers of bitumen-impregnated grade 3 geotextile as specified in Section A12.11 of Chapter 12.
The insides of the culverts shall be smooth and without any displaced joints. All pipes shall be laid true to line and level.
(i) Class A bedding
The pipe shall be laid with its bottom part on a C20/25-20 concrete bedding cradle of specified thickness below the lower part of
the pipe, which concrete shall extend upwards on both sides of the pipe to a specified portion of its height, as shown on the
drawings.
Before concreting, the pipes shall be supported on suitably shaped cradles at the correct level. No longitudinal construction joints
on the horizontal plane will be permitted.
(ii) Class B and Class C beddings
The pipe shall be laid on a bedding cradle of compacted selected granular material as specified. The bedding shall extend upwards
on both sides of the pipe to a specified portion of its height, as shown on the drawings. Grooves for thickened pipe ends, if
applicable, shall be formed in the bedding cradle for pipe sockets and couplings, to ensure that each pipe is fully supported
throughout the length of its barrel on the bedding cradle.
(iii) Class D bedding
The pipe shall be laid on the in situ material in the excavation bottom after the bottom has been hand trimmed to support the pipe
along the entire length of its barrel in accordance with the details shown on the drawings. Wherever necessary, the in situ material
shall first be stabilised in accordance with the details shown on the drawings or as prescribed by the Engineer. Grooves for
thickened pipe ends, if applicable, shall be formed in the trench bottom for pipe sockets and couplings, to ensure that each pipe is
fully supported throughout the length of its barrel on the bedding cradle.
(iv) Rock foundation
Where rock, shale or other hard material is encountered on the bottom of excavations, the installation of pipes on Class B bedding
shall proceed as follows:

The material below the pipe shall be excavated and replaced with a bed of sand or approved gravel or soil to a depth as shown on
the drawings or prescribed by the Engineer. Such material shall be classed as backfill for purposes of payment.
The backfill material shall be watered and compacted to provide a firm earth foundation. Class B bedding shall then be prepared
as described in Clause A3.2.7.7a)(ii).
(v) Concrete casing
Where shown on the drawings or specified by the Engineer, pipes shall be fully encased in concrete according to class and
dimensions as shown on the drawings or as ordered by the Engineer. Supports shall be provided close to the pipe ends to support
the pipes during the placing of concrete. The concrete shall be so placed as to fill all spaces below and around the pipe completely.
Poker vibrators shall be used for this purpose. Concrete casing shall be cast in one continuous operation until completed.
b) Prefabricated portal culverts
(i) Cast in situ floor slabs
Cast in situ floor slabs shall be constructed to the dimensions and at the locations as shown on the drawings or as may be
detailed on the drawings shall be formed in the floor slabs, as well as between the floor slabs and the inlet and outlet structures.
Where specified by the Engineer a screed layer shall be cast to the specified dimensions and details, prior to casting the floor slab.
In accordance with the drawings, transverse construction joints are required in cast in situ concrete invert slabs for portal culverts.
In addition, longitudinal construction joints as shown on the drawings between the invert slabs of each the barrels of multiple
culverts are required. Allowance for Class F1 surface finish and soft board in these joints is made in the schedule of quantities. No
payment shall be made for formwork on the outside edges of invert slabs (closest to the excavated face).
(ii) Prefabricated floor slabs
A layer of fine-grained material at least 75 mm thick shall be placed on the bottom of the excavation or backfilled bedding, leveled,
compacted and trimmed to line and grade, to form a bed to receive the prefabricated slabs.
The slabs shall be carefully placed on the prepared bed, true to line and grade, and so bedded that they will be uniformly supported
over their whole area on the bedding.
(iii) Placing the portal portions of culverts
The portal portions of portal and rectangular culverts shall be placed accurately and symmetrically on the floor slabs, with a thin
layer of mortar of one part of CEM I class 32.5 cement and six parts of sand between the contact surfaces to ensure a firm and
uniform support.
The units shall be butted end to end with butt joints, which joints (both horizontally and vertically) shall be covered externally with
two layers of grade 3 geotextile as specified in Section A12.11 of Chapter 12, pre-impregnated with a bituminous emulsion, or a
similar approved material. The strip of geotextile shall be at least 150 mm wide and placed symmetrically over the joint. The units
shall first be treated with a primer of 60 % bitumen emulsion over the width of the strip of geotextile.
Where two or more culverts are placed side by side to form a multi-barrel culvert, the space between the culverts shall be filled
with concrete up to the level of the top of the culvert.
c) Metal culverts
The excavation shall be trimmed to the shape of the invert of the culvert and a bed of fine granular material not less than 75 mm thick shall be
placed, compacted and shaped to enable the culverts to be bedded as shown on the drawings.
Where rock is encountered, the depth of excavation shall extend to a depth of at least 200 mm below the invert of the culvert, and shall be filled
with granular material as before.
The culverts shall be assembled and installed in accordance with the manufacturer's recommendations as specified by the Engineer. Where these
specifications are inconsistent with the manufacturer's recommendations, these specifications shall have preference. Anchor bolts shall be
installed at the ends of metal pipe culverts in accordance with the manufacturer's instructions to bond them into inlet and outlet head walls, which
head walls shall be constructed as soon as possible after installation of the culverts.
No concrete bedding or casing shall be used in the installation of metal culverts.
Where prescribed, the inner invert of metal culverts with diameters or spans exceeding 1 500 mm which are laid on steep grades shall be protected
with a layer of concrete with dimensions and class as shown on the drawings.
A3.2.7.8 Extension of existing culverts

Where an existing portal or rectangular culvert requires extension, the new section shall be constructed at the same grade and, where it joins the
existing structure, at the same level as the existing structure.
Any sections of existing wing walls, approach slabs and head walls, which may obstruct any new work, shall be demolished and removed. Existing
culvert ends shall not be damaged, but should damage occur, the repair work shall be done before the placement of any fresh concrete or
construction of the new culverts. Loose material shall be removed and joint faces thoroughly cleaned to the satisfaction of the Engineer.
Joining shall be done in accordance with Clause A3.2.7.13. After completion of the extension of a culvert, new approach slabs, head walls, wing
walls, catchpits, etc, shall be constructed in accordance with the drawings and Clause A3.2.7.11.
A3.2.7.9 Construction of culverts in half widths in existing roads

If necessary for accommodation of traffic or for any other reasons, or if so specified by the Engineer, culverts shall be constructed in half widths.
Unless otherwise prescribed, the downstream section shall be constructed first. The end of the excavation adjoining the traffic lane shall be
properly supported and shored up to prevent displacement or collapse from occurring. The necessary warning signs and barriers shall be erected
in accordance with the requirements of Section A1.5 of Chapter 1. No such work may be commenced with before safety barriers and traffic signs
have been erected.

Where the culvert is constructed in an existing road and it has been so prescribed by the Engineer, each of the pavement layers at least shall be
benched and recompacted during backfilling. The depth of benching shall equal the respective layer thicknesses, and the width shall be at least
150 mm.
A3.2.7.10 Backfilling of culverts

After the culverts have been constructed as described in Clauses A3.2.7.6 and A3.2.7.7, backfilling shall be carried out as follows:
No backfilling of a brickwork or in situ concrete structure may be done for a period of at least 7 days after the structure has been completed, unless
otherwise specified or directed by the Engineer. No backfilling of a brickwork structure may be done until the roof slab has been installed.
The material used for the backfilling of those portions of culverts subject to traffic loads shall be selected material of at least subbase quality or
such other lower quality as may be permitted by the Engineer. Where the excavated material is not of adequate quality, selected material shall be
imported for this purpose. The Contractor shall, in advance, ascertain from the Engineer as to which portions will require selected-quality material
for backfilling.
Backfilling alongside and over all culverts shall be placed at optimum moisture content and compacted in layers not exceeding 150 mm after
compaction, to a density of at least the density required for the material in adjoining layers of fill, subgrade and subbase. The density of backfilling
in excavations made in natural ground shall be at least 93 % of MDD.
Backfilling shall be carried out simultaneously and equally on both sides of a culvert to prevent unequal lateral forces from occurring.
Whenever specified or as may be specified by the Engineer, a wet or a stiff mixture of soil cement in lieu of a compacted gravel placed between
the side of the culvert and the excavation up to the top of the culvert shall be used.
The wet mixture of soil cement shall consist of an approved soil or gravel mixed with 5,0 % of CEM II class 32.5 cement and only sufficient water
to give a consistency that will permit the soil cement to be placed with vibrators, so that all voids between the culverts and the sides of excavations
and between culverts in the case of multi-barrel culverts will be properly filled. A stiff mixture of soil cement shall contain 3,0 % of CEM II class
32.5 cement and just sufficient water for it to be placed and compacted like ordinary backfill material. The height to which the soil cement backfill
shall be taken shall be as prescribed by the Engineer or shown on the drawings, and any remaining backfill shall be carried out as described
above with selected material.
The material used for soil cement shall preferably be a sandy material but may contain larger particles up to 38 mm, and it shall not have a
plasticity index exceeding 10. Detrimental percentages of silt or clay shall be avoided, and where the excavated material is not of adequate quality,
the material shall be obtained from an approved source.
The soil cement shall be mixed on the site with suitable concrete mixers, and the water and cement contents shall be carefully controlled. Should
the Contractor provide adequate quality control mechanisms for hand mixing, the Engineer may approve alternative mixing methods. The material
shall be placed and then thoroughly compacted so that all voids are filled as described above. At culvert ends stones shall be packed to prevent
the soil cement from flowing beyond the required limits.
All imported and backfill material shall be subject to the load and haul provisions specified in Section A1.7 of Chapter 1.
A3.2.7.11 Inlet and outlet structures, catchpits and manholes

Inlet and outlet structures for culverts as well as catchpits and manholes shall be constructed i n accordance with the details shown on the
drawings.
a) Excavation and backfilling
The specifications of Clause A3.2.7 in this Section for excavating and backfilling the culverts shall apply mutatis mutandis to inlet and outlet
structures, catchpits and manholes.
No backfilling of a structure may be done for a period of at least 7 days after the structure has been completed, unless otherwise specified or
b) Concrete work
The specifications of Clause A3.2.5.2a) in this Section for in situ concrete shall apply mutatis mutandis to inlet and outlet structures, catchpits and
manholes.
The type of surface finish for in situ concrete in the culverts shall be indicated on the drawings. Generally all exposed faces shall be of Class F2
formwork and faces covered by backfill shall be Class F1. The top parapet walls and wingwall shall be finished to a Class U2 surface finish.
c) Brickwork
The specifications of Clause A3.2.7.6b)(iv) for brickwork walls shall apply mutatis mutandis to inlet and outlet structures, catchpits and manholes.
d) Plaster
The specifications of Clause A3.2.7.6b)(v) for plaster shall apply mutatis mutandis to inlet and outlet structures, catchpits and manholes.
e) Manhole covers, grid inlets, etc
The specifications Clause A3.2.5.2f) for manhole covers and frames, grid inlets and other metal accessories shall apply mutatis mutandis to inlet
and outlet structures, catchpits and manholes.
f) Benching
All benching shall be rendered in 20 mm granolithic plaster and finished smooth and true with a steel trowel. Corners shall be rounded to
dimensions shown on the drawings.
g) Inlet and outlet structures.
Prefabricated concrete inlets and outlets shall not be installed until the installation procedures have been approved by the Engineer. Contractor
shall provide details of joining precast inlet and outlet elements to installed culverts as well as the bedding and backfill procedures to ensure that
the ingress of water and undermining of inlets and outlets is avoided. Cast in situ concrete wingwall type inlets and outlets shall be constructed
as indicated on the drawings and shall comply with the requirements of Section A13.4 of Chapter 13.

h) Prefabricated energy dissipaters in outlet structures
Where shown on the drawings, the Contractor shall supply and install in the outlet structures, prefabricated reinforced- concrete energy dissipaters
of class C25/30-20 concrete with dimensions as shown on the drawings. All concrete work shall comply with the requirements of Section A13.4
of Chapter 13.
A3.2.7.12 Removal of existing work

Where shown on the drawings or directed by the Engineer, existing inlets or outlets to culverts shall be demolished and debris or rubbish disposed
of as directed by the Engineer. Existing pipes shall be removed where necessary and saved for later use. All such work shall be carried out so as
to prevent damage being done to existing work, which is to remain.
The Contractor's attention is directed to the provisions of Section A1.6 of Chapter 1 that specifies which structures have to be removed as part of
the clearing and grubbing operations, the removal of which will therefore not be measured and paid for under this Section.
Undamaged recovered pipes may be re-used in the works where indicated by the Engineer. Recovered pipes which cannot be re-used shall
remain the property of the Employer and shall be stacked within the road reserve or where directed by the Engineer.
A3.2.7.13 Joining new work to old

Where partial or full demolition is required for extension work to existing concrete structures, the demolition and removal work shall be executed
as specified in Section A14.3 of Chapter 14. The provision of reinforcing anchoring shall be as specified in Section A14.5 of Chapter 14; and the
surface repair shall be executed as specified in Section A14.4 of Chapter 14. Larger concrete extensions shall be executed as specified under
the relevant concrete element for cast in situ concrete and paid under item C3.2.7.
A3.2.7.14 Sleeving or lining of existing culverts

Specifications for sleeving or lining of existing culverts, which have specific defects as well as the measurement and payment, shall be specified
under the Contract Documentation.
A3.2.7.15 Culverts on steep gradients

Where culverts are constructed on gradients exceeding 1 in 4, such culverts shall be referred to as inclined culverts. Inclined culverts shall be
constructed from the type of unit required, normally either circular concrete pipe units or metal culvert units as described in Clause A3.2.5.2.
Particular care shall be taken to protect excavations for inclined culverts against stormwater damage during the construction stage. The trenches
shall be excavated down to firm ground, and backfilled with selected gravel or concrete if it is necessary to over-excavate for obtaining a firm floor.
After the outlet structure has first been completed, the culvert units shall be laid in the normal manner by starting from the lower end and placing
successive units firmly against each other to prevent subsequent movement. The lower unit shall be securely cast into the outlet structure, and
metal culverts shall be provided with the necessary anchor bolts at both inlet and outlet structures and also at all thrust and anchor blocks.
Thrust and anchor blocks shall be constructed from concrete as required in accordance with the drawings and details furnished by the Engineer.
Anchor bolts, straps and other anchoring devices required at anchor and thrust blocks shall be provided.
The backfilling of trenches shall be done in horizontal layers starting at the lower end.
A3.2.7.16 Other stormwater pipes and closed conduits

Unless provided for elsewhere the specifications given in this Section for culverts, including the method of measurement and payment, shall apply
mutatis mutandis to the construction of pipes in closed or urban type stormwater systems, tremies or any other closed conduits constructed in situ
or from prefabricated units, whether intended for drainage or for any other purpose.
No distinction will be made in the schedule of quantities between the construction of culverts as defined elsewhere in Section A3.2 and that of the
other closed conduits described in this Clause A3.2.7.16, all being classed as culverts.
Tremies constructed from prefabricated units, shall be classed as inclined culverts where laid to a grade steeper than 1 in 4.
A3.2.8 WORKMANSHIP
order to ensure that the quality of materials produced will meet the specified requirements for the particular layer for which it will be used. These
required testing frequencies shall be stated in the borrow pit and quarry management and utilisation plans.
A copy of the Contractor’s process control test results, which should cover all the above quality control tests, shall be submitted to the Engineer
for comments.
A3.2.8.1 Construction tolerances and surface finish

a) Culverts
Culverts, inlets, outlets, catchpits and manholes shall be constructed to following tolerances:
(i) Horizontal alignment
The maximum deviation from the true position of the edges or centerline shall be 25 mm.
(ii) Vertical alignment
The invert level shall nowhere deviate by more than 25 mm from the required level and nowhere shall the inverts have an adverse
grade.

(iii) Trueness of exposed surface
When tested with a 3,0 m straight-edge, no exposed formed or cast concrete or precast surface shall have surface irregularities
exceeding 10 mm.
(iv) Cross-sectional dimensions
All cross-sectional dimensions shall be within 10 mm of the specified dimensions, and the average thickness of a floor, wall or roof
slab shall not be less than the specified thickness.
b) Surface finish
All unformed exposed concrete surfaces shall have a class U2 surface finish and all formed exposed concrete surfaces shall have a class F2
surface finish

B3.2 CULVERTS
CONTENTS
B3.2.1 SCOPE
B3.2.2 DEFINITIONS
B3.2.3 GENERAL
B3.2.5 MATERIALS

B3.2.8 WORKMANSHIP
B3.2.1 SCOPE
This Part covers additional specifications for work to enhance the labour component of construction activities, over and above labour employed
for conventional construction activities, where specified in Part A.
B3.2.2 DEFINITIONS
B3.2.3 GENERAL

B3.2.5 MATERIALS
B3.2.5.1 General material specifications


cubic metre shall be machine mixed with on site mechanical mixers and/or batch plants.
materials.
The selection of mixing and batching locations shall be so chosen to minimise the transport of concrete placement.
B3.2.7.2 Classes of Excavation

Materials
Description
Classification
Soft
hand-swung tool.
Intermediate

Materials
Classification

1
* Only applicable to materials comprising not more than 10 % gravel of size less than 10 mm and materials containing no cobbles or
B3.2.8 WORKMANSHIP

C3.2 CULVERTS
(i) Preamble
centre-line of the trench to the bottom of the specified bedding layer (as applicable).
pay items.
km.
specifications.
Clearing and grubbing A3.2.7.1; A3.2.7.12
items
Loading and hauling A3.2.7.5; A3.2.7.10
items

C3.2.1 Excavation for culvert structures:
C3.2.1.1 Excavating in all material situated within the following depth ranges below the surface level:

C3.2.1.2 Excavating soft material 0 m to 1,5 m below the surface level using labour enhanced cubic metre (m3)
construction methods, or instructed by hand under Clause A3.2.7.2d):
C3.2.1.3 Excavating intermediate material 0 m to 1,5 m below the surface level using labour cubic metre (m3)
enhanced construction methods, or instructed by hand under Clause A3.2.7.2d):
C3.2.1.4 Extra over sub-item C3.2.1.1 for excavation in hard or boulder material, cubic metre (m3)
irrespective of depth
C3.2.1.5 Extra over sub-item C3.2.1.1 for excavation in stabilised existing road layers, irrespective of cubic metre (m3
depth
The unit of measurement shall be the cubic metre of material excavated within the specified widths over the lengths and depths authorised by the
Engineer in each case, measured in place before excavation. Excavation in excess of the widths specified or authorised by the Engineer shall not
be measured for payment.
When measuring excavation for the removal of existing culverts, the volume occupied by the culvert shall not be subtracted from the calculated
volume of excavation.
In the case of manholes, catchpits and inlet and outlet structures, the dimensions for determining the volume of excavation shall be the neat
outside dimensions of the structure, plus an allowance of 0,5 m of working space around the structure.
Payment made for either hard; boulder or stabilised existing road layers shall only be measured for the one applicable extra over category.
The tendered rates shall include full compensation for all excavation, temporary timbering, shoring and strutting, for preparing the bottom of the
excavation for the culvert beds, the disposal of excavated material unsuitable for backfilling, keeping excavations safe, dealing with any surface
or subsurface water, and for any other operations necessary for completing the work as specified.
Excavation shall be done using conventional construction methods and/or labour enhanced construction methods as specified and measured.
The tendered rates shall include full compensation for the excavation of the material to the required dimensions, lines, levels and grades, the
trimming of the bottom of the excavation and the loading and disposal/utilisation of the materials directed, including haul of 1,0 km when using
conventional construction methods.
excavation of material is specified by means of labour enhanced construction methods, the tendered rates shall include loading and transport by
wheelbarrow if the material is disposed of or utilised within a radius of 50 m, alternatively loading by hand onto transport vehicles for such disposal
or utilisation elsewhere, within a haul distance of 1,0 km.
For payment purposes a distinction shall be made between materials as classified according to Clause A3.2.7.2a) under Classification of Materials.
C3.2.2 Backfilling:
C3.2.2.1 Using the excavated material cubic metre (m3)
C3.2.2.2 Using imported selected material:
(a) From commercial sources (State type) cubic metre (m3)
(b) From sources on site (State type) cubic metre (m3)
C3.2.2.3 Extra over sub-items C3.2.2.1 and C3.2.2.2 for soil cement backfilling
(a) With wet mixture (specify cement content) of 3 % cement cubic metre (m3)
(b) With dry mixture (specify cement content) of 3 % cement cubic metre (m3)
(c) Variation in cement kilogram (kg)
C3.2.2.4 Extra over sub-items C3.2.2.1 and C3.2.2.2 for screed layers (class of concrete indicated) cubic metre (m3)
The unit of measurement shall be the cubic metre of material backfilled in place after compaction. The quantity shall be calculated from the leading

dimensions of the backfilling as specified or as authorised by the Engineer.
If excavations were carried out in excess of the dimensions authorised by the Engineer, the quantity of backfilling will nevertheless be based on
the authorised dimensions. The volume occupied by the culvert shall be subtracted when calculating the volume of backfilling.
The tendered rates for item C3.2.2.2 shall include full compensation for backfilling under, alongside and over culvert structures, for watering, and
for compacting the backfill material to the specified density. The tendered rate for item C3.2.2.2(a) shall include full compensation for procuring,
furnishing and hauling G5 material from commercial suppliers, including the cost of transporting the material to the site irrespective of haul distance,
and placing the materials as specified. The tendered rates for item C3.2.2.2(b) shall, in addition, include full compensation for supplying selected
material of subbase quality from approved sources on site.
The tendered rates for item C3.2.2.3 shall be additional to the rates tendered for items C3.2.2.1 and C3.2.2.2 and shall include full compensation
for all additional cost to backfill material using labour enhanced methods of construction.
The tendered rates for items C3.2.2.3 and C3.2.2.4 shall be additional to the rates tendered for items C3.2.2.1 and C3.2.2.2 and shall include full
compensation for all incidentals required for the complete backfilling with soil cement or concrete screed as specified.
Variations will be dealt with in accordance with C1.1.4 of Chapter 1.
C3.2.3 Concrete pipe culverts:
C3.2.3.1 On Class A bedding (type and diameter indicated) metre (m)
C3.2.3.2 On Class B bedding (type and diameter indicated) metre (m)
C3.2.3.3 On Class C bedding (type and diameter indicated) metre (m)
C3.2.3.4 On Class D bedding (type and diameter indicated) metre (m)
C3.2.3.5 Provision of skew ends of pipe culvert (type and diameter indicated) number (No)
The unit of measurement for concrete pipe culverts shall be the metre of culvert laid as shown on the drawings or ordered by the Engineer. The
length shall be measured along the soffit centre of the culvert or along each barrel for multiple barrel units. The unit of measurement for the skew
ends of culverts shall be the number of skew end units provided; in- and outlets and multiple barrels shall be measured separately. The tendered
rate shall include for all costs to provide the skew end unit from the manufacturer to the specified length and skew including all wastage.
The tendered rates shall include full compensation for providing, testing, loading, transporting and unloading the culverts, for providing and placing
all specified bedding but excluding concrete bedding, and for the installation, laying and jointing of the culverts, as specified.
Where a half-length pipe unit is required, i.e. a pipe unit of which the length is equal to half the standard length, and provided that such half-length
pipe units are normally supplied by the manufacturers, the actual length of such half-length pipe unit will be measured for payment, and no
additional compensation will be paid in respect of such half-length pipe unit.
For the purposes of payment, differentiation shall be made between the various types and sizes of culverts and between the culverts placed on
A, B, C and D Classes of bedding as well as the different size skew ends requirements.
C3.2.4 Metal and U-PVC culverts:

C3.2.4.1 Size, wall thickness and type indicated metre (m)
C3.2.4.2 Provision of skew or bevelled ends for metal culverts number (No)
C3.2.4.3 Anchor bolts (size and type indicated) number (No)
C3.2.4.4 Protective coating to metal culverts (culvert size; inside/outside/ both sides; coating type & metre (m)
thickness indicated)
The unit of measurement for metal culverts and protective coating shall be the metre of culvert laid as shown on the drawings or ordered by the
Engineer. The unit of measurement for the skew/bevelled ends of culverts shall be the number of skew/bevelled end units provided; in- and outlets
and multiple barrels shall be measured separately. In the case of a metal or U-PVC pipe, the culvert length shall be measured along the pipe
centreline. In the case of a metal pipe arch, the culvert length shall be measured along the bottom/invert of the pipe arch. In all cases the length
of bevelled and/or skew ends shall be included.
The tendered rates shall include full compensation for providing, testing, loading, transporting and off-loading the culverts, for providing and placing
fine-grained material where required for the installation of culverts, and for installing, laying and jointing the culverts as specified. For the purposes
of payment, a differentiation shall be made between the various types and sizes of culverts and also between culverts with differing wall
thicknesses.
Payment shall be made separately for the provision of bevelled and/or skew ends for metal culverts, and the tendered rate shall include full
compensation for all work in connection with the provision of specified ends. U-PVC culverts may be cut to skew ends, but no additional payment
will be made for cutting skew ends.
The tendered rate per anchor bolt shall include full compensation for procuring, providing and installing the bolts.

C3.2.5 Rectangular culverts with prefabricated elements:
C3.2.5.1 Prefabricated portal culverts; wall and roof combination (size and type indicated) metre (m)
C3.2.5.2 Prefabricated floor slabs (size and type indicated) metre (m)
C3.2.5.3 Prefabricated roof slabs (size and type indicated) metre (m)
Payment will be made separately for cast in situ concrete wall, floor and/or roof slabs as well as formwork of culverts under item C3.2.7; and for
brickwork walls and plastering under items C3.2.16 and C3.2.17.
The unit of measurement for rectangular culverts constructed of prefabricated elements shall be the metre of culvert as per the relevant item(s)
constructed as shown on the drawings or as specified by the Engineer. Payment for a culvert may be made as a combination of prefabricated
elements as relevant.
The length shall be measured along the centre of the soffit of the culvert or along each barrel of multiple barrel units.
The tendered rates shall include full compensation for the supply and installation of all precast materials required to complete the culverts,
supplying, testing, loading, transporting and off-loading of all prefabricated portals, floor and roof slabs, providing and placing the fine-grained
material where required for installing the prefabricated culvert floors, and installing, laying and jointing the prefabricated slabs as specified,
including cutting them on the site, and waste. Where precast elements are installed on cast in situ concrete floors or walls or on brickwork walls,
no additional payment shall be made for any additional costs arising from the change between cast in situ and precast work.
Payment shall distinguish between the different sizes of rectangular culverts precast elements.
Payment for inlet and outlet structures shall be measured separately as specified in accordance with items C3.2.7 and C3.2.18 to C3.2.21 and
such other items as may be necessary.
C3.2.6 Extra over items C3.2.3, C3.2.4 and C3.2.5 for constructing inclined culverts metre (m)
The unit of measurement shall be the metre of culvert installed at a grade steeper than 1:4 as specified in Clause A3.2.7.15.
The tendered rate shall include full compensation for additional or more difficult work of any nature in regard to laying, excavating and backfilling
as may be required for installing the culverts at a grade steeper than 1:4.
C3.2.7 Cast in situ concrete and formwork:

C3.2.7.1 In Class A bedding, screeds, concrete backfill and the encasing for pipes, including formwork, cubic metre (m3)
(class of concrete indicated)
C3.2.7.2 In complete in situ floor slabs for rectangular culverts, manholes and catchpits including cubic metre (m3)
formwork, joints and Class U2 surface finish (class of concrete indicated) (installed at a
standard depth of 1,0 m)
C3.2.7.3 In walls, excluding formwork but including Class U2 surface finish (class of concrete indicated) cubic metre (m3)
C3.2.7.4 In roof slabs for rectangular culverts, excluding formwork but including Class U2 surfacing cubic metre (m3)
finish and joints (class of concrete indicated)
C3.2.7.5 In inlet and outlet structures including kerbs, chutes and downpipes, skewed ends, catchpits, cubic metre (m3)
manholes, thrust and anchor blocks, excluding formwork but including Class U2 surfacing finish
(class of concrete indicated)
C3.2.7.6 Formwork of concrete under items C3.2.7.3 to 5 above (Class of finish indicated) square metre (m2)
C3.2.7.7 Concrete linings for the inverts of metal culverts, including formwork and Class U2 surface cubic metre (m3)
finish (class of concrete indicated)
Measurement of formwork and cast in situ concrete shall be as specified in Section A13.4 of Chapter 13 of these specifications.
Payment for formwork and cast in situ concrete shall be made as provided in Chapter 13 of these specifications, except that payment for the
formwork for concreting in items C3.2.7.1 and C3.2.7.2 shall not be made separately, and the Contractor's rates for concrete shall include full
compensation therefore item C3.2.7.2 shall be subject to an extra over payment under item C3.2.15.4 in the case of manholes or catchpits deeper
than 1,0 m.
No separate payment shall be made for the construction of joints in culvert floor and roof slabs or at inlet and outlet structures and the tendered
rates for concrete shall include full compensation for forming the joints complete in accordance with the details shown on the drawings.
The tendered rates shall also include full compensation for mixing and/or procuring concrete as indicated, curing and the transport thereof to the
final placement location.
C3.2.8 Concrete backfill or encasement for culverts (Type and Class of concrete indicated) cubic metre (m3)
Measurement of cast in situ concrete shall be as specified in Section A13.4 of Chapter 13 of these specifications.

The quantity shall be calculated from the dimensions of the excavation as specified or as may be authorised by the Engineer, minus the volume
taken up by the culverts, irrespective of whether the actual excavation to be backfilled exceeds the specified or authorised dimensions.
The tendered rates shall also include full compensation for mixing and/or procuring concrete as specified, and the transport thereof to the final
placement location.
C3.2.9 Prefabricated concrete inlets and outlets to culverts (size and type indicated) number (No)
Prefabricated concrete inlets and outlets for concrete pipe culverts shall be measured per inlet or outlet, complete in position.
The tendered rate shall include full compensation for procuring, providing, loading, transporting, off-loading and installing the inlets or outlets as
specified.
C3.2.10 Reinforcement:
C3.2.10.1 Mild steel bars ton (t)
C3.2.10.2 High-tensile steel bars ton (t)
C3.2.10.3 Welded steel fabric kilogram (kg)
C3.2.10.4 Other material (specify) kilogram (kg)

Measurement and payment for steel reinforcement shall be made as specified in item C13.3.1 of Chapter 13. Measurement under this item shall
be limited to steel reinforcement as specified for complete cast in situ structures as measured under item C3.2.7. Steel reinforcement for composite
structures measured under other items shall be deemed to be included under such items.
C3.2.11 Anchoring of reinforcing steel: number (No.)

Reinforcing (type, bar diameter) into formed holes (hole diameter and depth stated) in
(description of member)
The unit of measurement and tendered rate shall be as specified under item C14.5.1 of Chapter 14.
C3.2.12 Demolition of concrete members or elements:
C3.2.12.1 Full member or element (location and description) cubic metre (m3)
C3.2.12.2 Partial member or element (location and description) cubic metre (m3)
The unit of measurement shall be the cubic metre of existing concrete removed according to authorised dimensions.
The tendered rates shall include full compensation for all demolition as specified in item C14.3.1 of Chapter 14.
C3.2.13 Removing and re-laying existing culverts:
C3.2.13.1 Removing and stacking existing culverts for re-use (size and type indicated) metre (m)
C3.2.13.2 Removing and re-laying existing culverts without stacking (size and type of bedding metre (m)
indicated)
C3.2.13.3 Re-laying existing culverts from stacking (size and type of bedding indicated) metre (m)
The unit of measurement shall be the metre of existing pipe or prefabricated portal culvert removed, stacked and/or re-laid.
The tendered rate shall include full compensation for lifting, loading, transporting for a haul distance within 5,0 km without additional payment, off-
loading, stacking (if required) and laying pipes according to the specifications.
Payment for any excavation and backfilling required for the removal and relaying of existing pipes or portals shall be made separately under items
C3.2.1 and C3.2.2.
C3.2.14 Protective mastic asphalt coating for corrugated metal culvert units (state whether square metre (m2)
to be applied by brush or by spray gun)
The unit of measurement shall be the square metre of protective coating applied as specified and as directed by the Engineer. When both inside
and outside surfaces are treated, both surfaces shall be measured.
The tendered rate shall include full compensation for procuring and furnishing the mastic asphalt, applying the material, and for all other additional
work and incidentals required for providing the protective coating as specified.

C3.2.15 Manholes and catch pits, with prefabricated elements
C3.2.15.1 Prefabricated floors (installed at a standard depth of 1,0 m):
(a) Size and type indicated- number (No)
(b) Size and type indicated(etc) number (No)
C3.2.15.2 Prefabricated roofs:
(a) Size and type indicated number (No)
(b) Size and type indicated(etc) number (No)
C3.2.15.3 Prefabricated walls
(a) Size and type indicated metre (m)
(b) Size and type indicated(etc) metre (m)

C3.2.15.4 Extra over item C3.2.15.1 and C3.2.7.2 for variations in the depths of all types of concrete metre (m)
manholes with prefabricated, or in situ concrete or brickwork wall combinations deeper than
1,0 m designated for tendering purposes
The unit of measurement, in the case of items C3.2.15.1 and 2 above for prefabricated manhole or catchpit floor or roof elements, shall be the
number of complete precast units as shown on the drawings or as specified by the Engineer, including covers, frames, grids and other accessories.
Item C3.2.15.1 shall be subject to an extra over payment under item C3.2.15.4 in the case of manholes or catchpits deeper than 1,0 m. The unit
of measurement, in the case of items C3.2.15.3 above for prefabricated manhole or catchpit wall elements, shall be the metre of full depth of
complete precast units as shown on the drawings or as specified by the Engineer. Payment for a manhole or catchpit may be made as a
combination of prefabricated elements as relevant.
The tendered rates shall include full compensation for the supply and installation of the complete precast units required to complete the manholes
and catchpits supplying, testing, loading, transporting and off-loading of all prefabricated walls, floor and roof slabs, providing and placing the fine-
grained material where required for installing the prefabricated culvert floors, and installing, laying and jointing the prefabricated elements as
specified, including cutting on the site, and waste. Where precast elements are installed on cast in situ concrete floors or walls or on brickwork
walls, no additional payment shall be made for any additional costs arising from the change between cast in situ and precast work. The tendered
rate shall also include full compensation for connecting up to and building any conduits into the walls of the various structures.
The unit of measurement in the case of items C3.2.15.4 above shall be the metre of increased depth of each manhole or catchpit measured once
only per manhole or catchpit in relation to the standard depth furnished for tendering purposes over items C3.2.7.2; or item C3.2.15.1, as
applicable. The tendered rates per metre, deeper than 1,0 m, shall be an adjustment to the compensation for the standard item, payable as an
increased compensation to the Contractor in relation to the standard depth. The tendered rate shall include for costs for the increase in
compensation for all additional costs arising for working to greater or depths, but excluding any additional excavation, backfill, in situ concrete,
brickwork or plaster. Where the above items of work cannot be conveniently standardised for payment according to complete units, the various
types of work and items of material provided shall be measured separately in accordance with items C3.2.7 and C3.2.16 to C3.2.19 and such
other items as may be necessary.
Measurement and payment will be made separately for cast in situ concrete for wall, floor and roof slabs as well as formwork of manholes and
catchpits under item C3.2.7, and for brickwork walls and plaster under items C3.2.16 and C3.2.17.
Excavation shall be measured and paid under item C3.2.1, and backfilling under item C3.2.2.
C3.2.16 Brickwork (Engineering bricks):
C3.2.16.1 115 mm thick square metre (m2)
C3.2.16.4 Specify thickness square metre (m2)

The unit of measurement shall be the square metre of engineering brickwork built, calculated from the leading dimensions of the brickwork. Areas
in walls occupied by conduits shall not be included in the areas measured, and corners and intersections common to more than one brickwall
shall be measured only once.
The tendered rates per square metre shall include full compensation for the brickwork complete as specified, including pointing and the building-
in of conduits.
Concrete and steel reinforcing used in reinforced brickwork walls shall be measured separately under items C3.2.7 and C3.2.10.

C3.2.17 Plaster square metre (m2)
The unit of measurement shall be the square metre of plasterwork provided.

The tendered rate shall include full compensation for raking out joints in the brickwork and applying a 1:4 plaster, as specified, to all surfaces
where required.
C3.2.18 Benching cubic metre (m3)
The unit of measurement shall be the cubic metre of benching, measured in plan, constructed in class C20/25-14 concrete with granolithic
rendering.
The tendered rate shall include full compensation for procuring and furnishing all materials, placing the concrete benching, and rendering with the
specified granolithic rendering.
C3.2.19 Accessories:
C3.2.19.1 Manhole frames (description and reference to drawing) number (No)
C3.2.19.2 Inlet grids or covers (description and reference to drawing) number (No)
C3.2.19.3 Manhole frames (type, load bearing and SANS specification indicated) number (No)
C3.2.19.4 Manhole covers or gratings (type, load bearing and SANS specification indicated) number (No)
C3.2.19.5 Inlet channel frames (type, load bearing and SANS specification indicated) number (No)
C3.2.19.6 Inlet channel gratings (type, load bearing and SANS specification indicated) number (No)
C3.2.19.7 Step irons (description and SANS specification indicated) number (No)
C3.2.19.8 (Etc for other accessories) number (No)
The unit of measurement shall be the number of each type of accessory delivered and installed. Accessories shall only be measured and paid
where such items are not included in unit prices for complete structures such as under item C3.2.15
The tendered rates shall include full compensation for procuring, furnishing and installing the accessories as specified.
C3.2.20 Anchors for pipes (description) number (No)
The unit of measurement shall be the complete anchor installed, including straps, bolts, etc, but excluding any concrete work, which shall be
measured under item C3.2.7.
The tendered rate shall include full compensation for procuring, providing and installing the anchors.
C3.2.21 Prefabricated reinforced-concrete skew end units for concrete culverts constructed at number (No)
a skew angle ( type and dimensions of unit and class of bedding indicated)
The unit of measurement shall be the number of each type and size of prefabricated reinforced-concrete skew end unit provided and installed,
irrespective of the angle of skew.
The tendered rates shall include full compensation for providing, testing, loading and unloading the units, constructing the prescribed class of
bedding, and for installing, laying and joining the units, complete as specified and in accordance with the details shown on the drawings.
C3.2.22 Cutting of concrete pipes (diameter indicated) number (No)
The unit of measurement shall be the number of pipes that have been cut on the instruction by the Engineer. The tendered rate shall be fill
compensation for the cutting, by means of mechanical saw (angle grinder) and finishing off the pipes for the specific angle of skew at which the
pipes must be laid.
Cutting of the pipes shall only be paid for if the headwall or the wingwalls are at such a skew angle in respect to the centre line of the pipes that
cutting is required and where non-standard lengths are required. The maximum skew angle at which pipes are allowed to be cut shall be 30
degrees and the maximum length of pipe measured along the shortest side, shall be 1,5 m.

C3.2.23 Breaking into existing drainage structures and building in pipes or culverts of the number (No)
following size (pipe diameter and/or culvert size to be stated)
The unit of measurement is the number of each type and size of existing drainage structure that is being modified as shown on the drawings or
as specified by the Engineer.
The tendered rates shall include full compensation for providing all labour, constructional plant and materials required, for all excavation, breaking
into existing drainage structures, building into the newly formed accesses, sealing around the edges and making the joints watertight, breaking
out existing benching and channelling where required and reconstructing them complete with granolithic rendering to suit the new drainage
arrangement, backfilling and compacting to at least 93 % of MDD and dealing with the flows in the existing structures.
C3.2.24 Compaction of bedding for inlets, outlets, manholes and catchpits:
C3.2.24.1 Preparation and compaction of in situ bedding material to 90 % of MDD (depth indicated) cubic metre (m³)
C3.2.24.2 Extra-over sub-item C3.2.24.1 for compaction to 93 % of MDD (depth indicated) cubic metre (m³)
The unit of measurement shall be the cubic metre of material ripped and compacted as specified.
The tendered rate shall include full compensation for the ripping of the in situ material to the specified width and depth, wetting the material to
such an extent that the density can be achieved.
C3.2.25 Painting of exposed steel bars with two coats of zinc rich primer (Type specified) litre (ℓ)
The unit of measurement shall be the litre of primer used as specified

The tendered rate shall include full compensation for cleaning the exposed steel as specified and providing and applying the primer in accordance
with the manufacturer’s specifications.
C3.2.26 Repair with cementitious mortar or concrete (Class) to (description) litre (ℓ)
The unit of measurement shall be the litre of mortar or concrete as specified by the Engineer and measured in place, used for the repair of specified
concrete defects, including curing.
The tendered rate shall be as specified under item C14.4.1 of Chapter 14. Payment for larger concrete extensions shall be made under item
C3.2.7.
C3.2.27 Repair with epoxy mortar litre (ℓ)

The unit of measurement is the litre of epoxy mortar measured in place, of specified type used for the repair of specified concrete defects,
including curing.
The tendered rate shall be as specified under item C14.4.2 of Chapter 14.

D3.2 CULVERTS
CONTENTS
D3.2.1 SCOPE
D3.2.2 GENERAL

3.3 CONCRETE KERBING AND CHANNELING, ASPHALT BERMS,
CHUTES, DOWNPIPES, AS WELL AS CONCRETE, STONE
PITCHED AND GABION LININGS FOR OPEN DRAINS
CONTENTS
A3.3.1 SCOPE
A3.3.2 DEFINITIONS
A3.3.3 GENERAL
A3.3.5 MATERIALS
A3.3.8 WORKMANSHIP

PART C: MEASUREMENTS AND PAYMENTS
A3.3 CONCRETE KERBING AND CHANNELING, ASPHALT BERMS,

CHUTES, DOWNPIPES, AS WELL AS CONCRETE, STONE PITCHED
AND GABION LININGS FOR OPEN DRAINS
A3.3.1 SCOPE
Drainage under this Section mainly covers the drainage of road and bridge surfaces into open structures or conduits. Drainage may transfer into
culverts or conduits or to natural or formed drainage channels. This Section covers work in connection with the construction of concrete kerbing
and its channeling, asphalt berms, kerb inlets, chutes, downpipes, and linings for open drains constructed from concrete, stone pitching, gabions,
mattresses or alternative materials at the locations and to the details as shown on the drawings or specified by the Engineer. This Section also
covers the replacement of damaged kerbing, channeling, asphalt berms, and lining of all types of construction.
A3.3.2 DEFINITIONS
A3.3.3 GENERAL
A3.3.3.1 Types of structures
Kerbing shall include barrier kerbs, mountable and semi-mountable types. All these elements may be prefabricated on site or elsewhere or
constructed in a continuous operation using slipforms. Kerb inlets shall generally be cast in situ concrete.
Channeling may be cast in situ concrete, prefabricated units, slipform construction, stone pitched or gabion lined.
Chutes may be prefabricated units, cast in situ concrete, stone pitched or gabion lined.
Lining of open channels may be cast in situ concrete or stone pitched or gabions, except that side slabs may be precast on site or elsewhere.
Downpipes shall be prefabricated elements, of concrete, steel or U-PVC or HDPE.
Asphalt berms may be cast in situ in moulds or constructed by means of a suitable machine.


A3.3.5 MATERIALS
The material specifications are the required specifications for the materials as placed and/or processed in its final position on the road.
It is the Contractor’s responsibility to ensure that the materials delivered to the road shall meet these specified requirements. All precast and
manufactured elements are to be tested for strength and durability.
A3.3.5.2 Drainage structure materials

a) Concrete
All concrete work shall be carried out in accordance with the requirements of Section A13.4 of Chapter 13 of these specifications, read together
with the provisions of Clause A3.1.5.4.
b) Cement
Cement shall comply with SANS 50197-1 for CEM I or CEM II with a strength class of 32,5 or greater, and a rate of strength gain N or greater.
c) Kerbing and channeling
Prefabricated kerbing and channeling shall be manufactured on site or elsewhere and shall comply with the requirements of SANS 927. Cast in
situ kerbing and channeling shall be of the class of concrete indicated.
d) Joint sealant
Two-part cold applied polysulphide sealing compound shall conform to the requirements of BS 4254.
Polyurethane-based joint sealants shall comply with the requirements of SANS1077.
Silicone-based joint sealants shall comply with the requirements SANS 1305 unless otherwise indicated in the Contract Documentation.
e) Bedding material
Concrete as bedding or backing material, in shall be a class C16/20-20 cast in situ concrete.
Alternative bedding shall consist of crushed stone, cinders, slag, sand or other approved porous material with a maximum particle size of 14 mm.
f) Asphalt berms
Asphalt berms shall be bedded on completed surfacing layers or primed base layers. Asphalt shall be a continuously graded fine or medium mix,
as specified, with aggregate grading as specified in Table A9.1.5-5 of Chapter 9 and mix properties as specified in Table A9.1.3-2 of Chapter 9.
g) Stone
Stone for pitching shall be sound, tough and durable, with 80 % of stones more than 150 mm in minimum dimension, with smaller pieces or spalls
may be used for filling spaces between the larger stones. The shapes of the rocks or stones shall be so as to form a stable protective layer of the
required thickness. Rounded boulders shall not be used on slopes steeper than 2:1 unless cement grouted.
h) Sand for concrete
Sand for concrete, cement slurry and cement mortar shall comply with the requirements of SANS 1083.
i) Gabions and mattresses
The materials used for the construction of gabions and mattresses which may include rock, PVC-coated and/or galvanized wire and wire mesh
shall comply with the requirements of Section A12.6 of Chapter 12.
j) Geotextiles
Geotextiles shall be of the grade and type specified in the schedule of quantities or Contract Documentation, and shall comply with the
requirements of Section A12.11 of Chapter 12.
k) U-PVC pipes
U-PVC pipes shall comply to the requirements of SANS 791 for solid wall pipes (category-heavy duty), and shall have socketed ends should
joining be required.
l) Bituminous binders
Should a prime coat be required, it shall conform to the specifications of the prime for the base layer.
The bond coat shall consist of a stable grade bituminous emulsion diluted to have 30 % net bitumen content
The bituminous binder to be used in the specified mix shall be a bitumen emulsion and conform to the specifications in Clause A9.1.5.2 of Chapter
9.
m) Polymer film sheeting
Plastic for drainage systems to be used shall be polymer film type sheeting of 150 to 250 micron (0,15 to 0,25 mm) thickness, complying with
complying with SANS 952-1
n) Alternative materials
Alternative materials, if any, shall be specified and detailed in the Contact Documentation. Where alternative materials are proposed by the
Contractor, they shall be submitted for approval, accompanied by the verification of being fit for purpose, specific performance guarantees.

The Contractor shall submit his plant and equipment list for excavating, stockpiling if specified, manufacturing, loading, hauling and all construction
as part of his method statement to perform the different elements of the Works.

A3.3.7.1 Drainage structures
a) Excavation and preparation of bedding
(i) Kerbs and channels
Trenches for kerbs and channels and inlets and outlets thereto shall be excavated to the required depth and all unsuitable material
shall be removed and replaced with a layer of approved bedding material at least 75 mm thick. The bedding shall be compacted
and accurately shaped to the required grade and level. No in situ concrete or precast concrete units shall be placed on
uncompacted or disturbed material.
(ii) Asphalt berms
If indicated on the drawings or specified by the Engineer, the base layer prime coat shall extend wider to cover the area where the
berms are to be constructed. Asphalt berms should be constructed after the completion of surfacing and any vehicle restraint
systems in order to minimise the risk of damage.
Before any specified berms or priming commences, the specified width of the base projecting beyond the surfacing shall be
thoroughly cleaned. The shoulder material adjacent to the base shall be compacted and trimmed to match the upper level of the
base, and all loose material removed.
The bond coat shall consist of a stable grade bituminous emulsion diluted to have a 30 % net bitumen content and shall be applied
at a rate of 0,4 litres per square metre onto the entire berm foundation. The bond coat shall be left to dry before the berm is
constructed.
Production and placement of asphalt shall be as specified in Section A9.1 of Chapter 9.
(iii) Linings for open drains
The excavation work for open drains and clearing and grubbing if required, shall be executed and paid for under and in accordance
with the provisions of Section A3.1.
The excavations shall then be neatly trimmed to the lines and levels specified so as to permit the accurate construction of the
linings. All loose material shall be compacted to a density of not less than 93 % of MDD.
Where the in situ material is unsuitable, the Engineer may instruct that it be removed to the required depth and replaced with
selected material compacted to a density of 93 % of MDD to the required grade and level.
Where stone pitching or gabions are specified, the area shall be prepared by excavating, shaping and trimming as necessary for
pitching or gabions, and by thoroughly compacting the area by hand-ramming to prevent subsequent settlement. A trench shall be
excavated as directed by the Engineer along the toe of any slopes to be lined or along the unprotected edge of the linings in the
beds of streams to allow the construction of a thickened edge of the specified lining.
Where excavations for open drains are in rock, overbreak shall be backfilled as specified, either with mass concrete or with selected
gravel or soil compacted to a MDD of at least 93 %.
(iv) Chutes
Excavations for chutes shall be neatly trimmed. All loose material shall be thoroughly compacted, and where overbreak occurs in
hard material, the excavations shall be backfilled with mass concrete.
b) Prefabricated concrete kerbing and channeling
Unless otherwise specified in the Contract Documentation, prefabricated concrete kerbs shall be laid with a class C16/20-20 cast in situ concrete
bedding and support behind the kerbs in accordance with the details shown on the drawings.
Prefabricated concrete kerbing and channeling shall be laid on the approved bedding with close joints filled with 3:1 sand: cement mortar not
exceeding 10 mm in thickness and neatly pointed with a pointing trowel. The exposed faces of kerbs and edging shall be constructed true to line
and level. Kerbing around curves shall first be laid along the full curve length before the joints are filled, unless otherwise allowed by the Engineer.
Kerbs shall be temporarily propped during construction.
Unless otherwise specified, prefabricated concrete kerb units shall be 1,0 m in length, except at curves at road junctions, where the kerb units shall
be 0,5 m in length for curve radii between 5,0 m and 20 m and 0,3 m in length for curve radii between 1,0 m and 5,0 m. For curves with a radius less
than one metre the kerbs shall be cast in situ. Any associated prefabricated concrete channeling units shall also comply with these length requirements.
Special care shall be taken to assure that expansion joints are constructed and sealed as shown on the drawings or specified by the Engineer.
c) Chutes and downpipes on side slopes of fills and cuts
(i) Prefabricated chutes and downpipes
Prefabricated chutes and downpipes shall be manufactured in accordance with the dimensions shown on the drawings, and the
units shall fit neatly into each other. The bottom unit shall rest against the outlet structure or footing as shown on the drawings.
The units shall be laid true to line and grade from the bottom up so that each unit fits neatly into the previous one. A transition
section shall be constructed at the inlet to lead the water into the chute or downpipe as shown on the drawings.
Downpipe joints shall socketed into each other with the external joint facing toward the inlet of the drain.

(ii) Stone pitched chutes
Stone pitched chutes shall be constructed as specified for stone pitched open drains as specified in Clause A3.3.7.1i).
d) Slip-form kerbing
Slip-form kerbs and channels shall be placed on an approved bedding by a continuous process with an approved slip form machine. Contraction
joints shall be sawn at intervals shown on the drawings or prescribed by the Engineer in a manner so as not to cause the concrete to spall at the
joint. The concrete shall be cured in accordance with the requirements of Section A13.4 of Chapter 13 or as specified by the Engineer.
The kerbs and channels shall be constructed true to line and elevation and shall have a neat appearance. Where transverse cracks occur, the
Contractor shall replace the entire section between the contraction joints, or as specified by the Engineer, at his own cost.
Curing shall be carried out strictly in accordance with the approved method statement, without damage to the completed kerbing or channeling.
Any such damage shall be made good according to the Engineer’s specification, at the Contractor’s cost
Special care shall be taken to ensure that expansion joints are constructed and sealed as shown on the drawings or specified by the Engineer.
e) Cast in situ kerbs and channels
Forms for kerbs and channels shall be accurately set to line and elevation and shall be firmly held in position during the placing of the concrete.
Stops and jointing material at the ends of sections shall be accurately placed so as to ensure that joints between adjacent sections are
perpendicular to the surface of the concrete and at right angles to the edge of the road.
After concrete has been placed in the forms, it shall be tamped and worked until mortar entirely covers any exposed faces. Exposed faces shall
then be finished to smooth and even surfaces and edges shall be rounded to the radii shown on the drawings.
Forms shall be removed from any concrete surfaces that will be exposed, within a period of 24 hours of the concrete having been placed. Minor
defects shall be repaired with a 2:1 sand: cement mortar. Plastering shall not be permitted on exposed faces and all rejected portions shall be
removed and replaced at the Contractor's cost. When completed, the sections shall be cured in accordance with the requirements specified in
Section A13.4 of Chapter 13 or as specified by the Engineer.
Special care shall be taken to assure that expansion joints are constructed and sealed as shown on the drawing or specified by the Engineer
The completed kerbs and channels shall be true to line and elevation and shall have an even and neat appearance.
f) Cast in situ chutes on cut slopes
Cast in situ concrete chutes on cut slopes, together with the inlet and outlet structures, shall be constructed in accordance with the drawings. The
class of concrete shall be as indicated on the drawings and/or indicated in the Contract Documentation. On slopes steeper than 1:2 cast in situ
concrete shall be constructed by boxed shuttering.
Where specified by the Engineer, a concrete screed shall first be cast on excavations that cannot be trimmed accurately. The screed shall be
accurately finished to the level of the underside of the chute floor slab and allowed to set before the floor slab is cast. Where the material being
excavated cannot be accurately trimmed or where the chute sides have to extend above the surface of cut slopes, the outer faces of the sides
shall be cast against formwork as specified by the Engineer
g) Asphalt berms
Berms shall be constructed with the toe of the berm not encroaching more than 25 mm into the surfacing of the adjacent roadway or shoulder.
When placed by hand, the asphalt shall be placed and shaped in situ in a rigid portable mould to form a trapezoidal berm of the dimension specified
or indicated on the drawings. The asphalt mixture shall be thoroughly compacted to form a hard unyielding berm, true to level, shape and line,
within the specified tolerances. The moulds may be removed as soon as the asphalt has cooled to air temperature, or, in the case of a cold asphalt
mixture, as soon as the berm has hardened and the mould can be removed without damage to the berm.
A machine of approved design may be used for placing the berm. In general machine placed berms will not require additional compaction but in
areas where compaction is inadequate, the machine shall be ballasted with additional mass, or other measures shall be taken to ensure that
adequate compaction is achieved.
Should the berms be constructed before the construction of vehicle restraint systems, the post holes shall be excavated with care to prevent
damage to the berms. Where chute or downpipe inlets are required against fills, the berm shall be discontinued until the inlet is constructed, and
thereafter finished to form a tie in with the inlet.
h) Concrete-lined open drains
The exposed surfaces of the concrete linings of open drains shall have a class U2 surface finish. Concrete shall be cured in accordance with the
requirements of Section A13.4 of Chapter 13.
Sealed joints in concrete shall be in accordance with the details indicated on the drawings as well as the provisions of Section A13.7 of Chapter
13. Cold joints shall be painted with a coat of approved bituminous emulsion containing 60 % of net bitumen by mass, or with an approved anti-
adhesive before any adjoining slabs are cast.
Expansion joints shall be made in accordance with the drawings.
Where required, the surfaces on which concrete lining is to be cast shall, after having been trimmed, be covered with polymer film sheeting of
0.15mm thickness and all joints in the sheeting shall be overlapped by at least 150 mm. Alternatively the surface could be sprayed with invert
bituminous emulsion as soon as possible after the excavations have been trimmed and compacted. The sprayed surfaces shall be maintained until
the concrete lining is cast. The nominal rate of application of the emulsion shall be 0,5 litre/m2 unless otherwise specified by the Engineer.
i) Stone pitched open drains
(i) Grouted stone pitching with mortar
The stones shall be thoroughly cleaned of adhering dirt or clay. Commencing from the bottom of the trench, the stone shall be
moistened and embedded in freshly laid cement mortar composed of one part of cement to every six parts of sand by volume. The
stones shall be firmly bedded against adjoining stones. The stones shall be laid with their longitudinal axes at right angles to the
slope and with staggered joints. Any spaces between the stones shall be filled with cement grout of the same composition as the
mortar. The mortar and grout shall be placed in a continuous operation for any day's run at any one location. The grout shall be
worked into the pitching so as to ensure that all spaces or voids between the stones will be completely filled with grout to the depth
of the stone pitching, with the approximately 20 mm of stones protruding. Grout spilt onto exposed surfaces of the stones shall be
removed while still soft, and the joints between stones shall be neatly finished.
The grouted pitching shall be cured with wet sacking or other approved wet cover for a period of not less than four days after
grouting, and shall not be subjected to loading until adequate strength has been developed. Where required and indicated on the
drawings and/or Contract Documentation, weep holes shall be formed in the pitching.
The thickness of the pitching including the stone protrusions, measured at right angles to the surface, shall not be less than 200
mm.
The completed pitching shall have an even appearance and nowhere may the grout surface deviate by more than 25 mm from the
specified lines and grades.
(ii) Grouted stone pitching on a concrete bed
The area to be pitched shall be prepared as described in Clause A3.3.7.1a)(iii) and a concrete bed (class C16/20-20 concrete)
with a thickness of at least 75 mm shall then be placed. The stone pitching shall be laid while the concrete is still workable.
Openings between stones shall be filled with cement grout and stone protrusion constructed as described in Clause A3.3.7.1i)(i),
and care shall be taken not to spill the grout onto the finally exposed surfaces of the stones. Grout spilt onto the exposed surfaces
of the stones shall be removed while still soft and the joints between stones shall be neatly finished.
Curing shall be done as described for grouted stone pitching in Clause A3.3.7.1i)(i).
The thickness of the pitching including the bedding and stone protrusions, measured at right angles to the surface, shall not be
less than 200 mm.
The completed pitching shall have an even appearance and nowhere may the grout surface deviate by more than 25 mm from the
specified lines and grades.
j) Gabion lined open drains
Generally 0,3 m thick mattresses will be used to line open drains.
Gabions and mattresses shall be constructed in terms of the requirements of Section A12.6 of Chapter 12. The stones used in the top layer of all
gabions shall be selected to resemble normal stone pitching.
k) Backfilling
After completing the concrete work, the spaces at the backs of kerbs shall be backfilled with approved material to pavement or road shoulder
level. Spaces adjoining open drains and chutes shall be backfilled level with the adjacent road or embankment surface. Such backfill shall be
placed in layers not exceeding 150 mm and each layer shall be thoroughly compacted at optimum moisture content before the succeeding layer
is placed thereon.
Where kerbs and channels are laid after construction of the base, the spaces between the concrete and adjoining base shall be backfilled with
approved premixed asphalt material.
l) Construction sequence
Where new base layers and kerb and channels are constructed, kerbs and channels shall be constructed before the construction of the adjoining
base layer unless otherwise approved by the Engineer.
Where kerbs and channeling are constructed before the base:
In this case slip-form units or cast in situ units may be constructed. During working and constructing the base, precautionary measures shall be
taken to prevent the concrete work from being damaged or disturbed.
Where kerbs and channeling are constructed after the granular base:
The base shall be constructed wider than the specified width, after which a neat trench shall be excavated for the kerbing or channeling. Any over-
excavation shall be back filled with concrete cast simultaneously with the kerbs and channeling.
Where kerbs and channeling are constructed after the asphalt base and/or asphalt surfacing:
The asphalt base and/or asphalt surfacing shall be constructed wider than the specified width and shall then be cut back accurately with a
mechanical saw to a marked line to give a neat joint line between the kerbs or channeling and the asphalt layer. The surfacing and base shall
then be removed to the required depth.
m) Protection
The Contractor shall take all precautions to prevent concrete spillage onto the adjacent completed road surfacing. Any concrete spilt onto the road
surface shall be removed. Where so required by the Engineer, the Contractor shall, without any additional compensation, sand blast the stained
surface and treated with bitumen emulsion to get an evenly coloured surface.
During transporting and laying, care shall be taken to protect all precast units against chipping or breakage.
Concrete kerbing and channeling as well as any other structures adjacent to the road shall be protected against staining by prime or bitumen
being sprayed or premix being placed. Where prime or bitumen is to be sprayed, all such work shall be completely covered with polymer film
sheeting at least 0,25 mm thick, specially reinforced paper or other approved material, properly secured to prevent the sheeting from lifting during
windy conditions. Any work stained by prime or bitumen shall be broken down and replaced, unless all such prime or bitumen is completely
removed so as not to show any stains. Painting over stained work will not be permitted.
n) Cutting existing bituminous surfacing and pavement layers
Where kerbing, channeling or concrete-lined drains to be constructed against existing bituminous surfacing is specified, the full depth of the
bituminous surfacing, and the base and subbase if necessary, shall be accurately cut with a mechanical saw to the required line and depth before
the kerbing, channeling or concrete-lined drain is constructed. The cut edge shall be vertical for kerbing and channeling. The concrete shall then
be cast directly against the cut edge without formwork. All material outside the cut edge shall be removed to the required depth before the concrete
is cast. The debris shall be disposed of at a dumping site to be provided by the Contractor subject to the approval of the Engineer. The bituminous
surfacing shall be protected and kept clean to the Engineer's satisfaction.

o) Demolition of existing kerb and channel and concrete lined drains
Where shown on the drawings and/or indicated by the Engineer, the existing kerb and channel and concrete lined drains shall be demolished to
a specified maximum size, removed and transported to an approved spoil site as provided by the Contractor. All adjoining existing work shall be
protected against damage during such excavation and removal. Any damage to such work shall be made good at the Contractor’s cost.
A3.3.7.2 Inlet and outlet structures and transition sections

Transition sections on kerbing, kerbing-channeling combinations and concrete-lined or stone pitched open drains shall be constructed to the same
standards and by the same methods as described for the uniform sections, but with the required modifications. Sections may be either precast or
cast in situ units.
Inlet and outlet structures may be either precast or partially precast concrete units or may be cast in situ concrete.
Where shown on the drawings or specified by the Engineer, the Contractor shall supply and install within the outlet structures, energy dissipaters
consisting of prefabricated reinforced-concrete blocks of class C20/25-20 concrete of the dimensions shown on the drawings or listed in the
schedule of quantities, or alternatively stones as detailed on the drawings shall be set in the freshly cast concrete.
Components or accessories such as grids, covers and frames shall be in accordance with the details shown on the drawings and the requirements
of Clause A3.2.5.2.
A3.3.8 WORKMANSHIP
order to ensure that the quality of materials produced will meet the specified requirements for the particular purpose for which it will be used.
A3.3.8.1 Construction tolerances and surface finish

a) Concrete kerbing and channeling
Concrete kerbing and channeling shall be constructed to within the following dimensional and alignment tolerances:
(i) Horizontal alignment
The maximum deviation of edges, centre line, or vertical surfaces from the specified position shall be 25 mm, read together with
the alignment tolerance hereunder.
The rate of deviation of edges, centre line, or vertical surfaces from the specified alignment, shall be less than 1:500 when taken
over any section exceeding 10 m in length.
(ii) Vertical alignment and level
Unless designed as such, the inside edge of channeling shall nowhere be above the finished road level nor more than 10 mm
below the finished road level. The invert level of channels and open drains and the top of kerbing shall nowhere deviate by more
than 10 mm from the required level and nowhere shall channels or drains have any adverse grade. Any ponding resulting from
such deviations shall be resolved as specified by the Engineer, which may include complete removal and reconstruction of the
affected section.
(iii) Trueness of exposed surfaces
When tested with a 3,0 m straight-edge, no surface irregularities shall exceed 6mm.
(iv) Cross-sectional dimensions
All cross-sectional dimensions shall be within 6,0 mm of the specified dimensions except that the underside of channeling may
extend up to 25 mm below the level at which it would have the required thickness.
b) Asphalt berms
Berms shall be placed true to level, shape and line. Berms shall not deviate more than 10 mm from the specified line when measured at the
inner edge of either their crests or bases. The height or width of berms shall not deviate by more than 5,0 mm form the specified height or width.
c) Concrete- and stone pitched-lined open drains, chutes and downpipes
Concrete- and stone pitched lined open drains, chutes and downpipes shall be constructed to following tolerances:
(v) Horizontal alignment
The maximum deviation from the true position of the edges or centerline shall be 25 mm.
(vi) Vertical alignment
The invert level shall nowhere deviate by more than 25 mm from the required level and nowhere shall the inverts have an adverse
grade.
(vii) Trueness of exposed surface
When tested with a 3,0 m straight-edge, no exposed formed or cast concrete or precast surface shall have surface irregularities
exceeding 10 mm.
(viii) Cross-sectional dimensions
All cross-sectional dimensions shall be within 10 mm of the specified dimensions, and the average thickness of a floor or side slab
shall not be less than the specified thickness when considering any complete slab or a slab section with a surface area of 10 m²
or more, and disregarding a thickness exceeding 10 mm of the specified thickness.

d) Surface finish
All unformed exposed concrete surfaces shall have a Class U2 surface finish and all formed exposed concrete surfaces shall have a Class F2
surface finish.

B3.3 CONCRETE KERBING AND CHANNELING, ASPHALT BERMS,
CONTENTS
B3.3.1 SCOPE
B3.3.2 DEFINITIONS
B3.3.3 GENERAL
B3.3.5 MATERIALS

B3.3.8 WORKMANSHIP
B3.3.1 SCOPE
This part covers additional specifications for work to enhance the labour component of construction activities, over and above labour employed
for conventional construction activities, where specified.
B3.3.2 DEFINITIONS
B3.3.3 GENERAL

B3.3.5 MATERIALS


materials.

The selection of mixing and batching locations shall be so chosen to minimize the transport of concrete placement.
B3.3.8 WORKMANSHIP

C3.3 CONCRETE KERBING AND CHANNELING, ASPHALT BERMS,
(i) Preamble
3. No separate payment will be made for the protection or repair as required of any existing or new road furniture, structures, infrastructure or
services damaged by the Contractor’s activities.
pay items.
km.
specifications.
Cast in situ concrete chutes – excavation trimming and
C3.3.7 C3.1 - All applicable items
gravel or soil backfilling
Gabion linings for open drains A3.3.7.1j) C11.2.3 of Chapter 11
Reinforcement C3.3.12 C13.3.1 of Chapter 13
Reinforcement – hot dip galvanizing C3.3.12 C13.9.3.2 of Chapter 13

Loading and hauling C3.3.16
items

C3.3.1 Concrete kerbing:
C3.3.1.1 Prefabricated kerbing (description of type of kerb and bedding with reference to drawing)
(a) State type of kerb and bedding with reference to drawing metre (m)
(b) Etc for other types metre (m)
C3.3.1.2 Cast in situ kerbing
(a) State type of kerb, class of concrete with reference to drawing metre (m)
The unit of measurement shall be the metre of concrete kerbing complete as specified and detailed on the drawings, measured along the front
face of the kerb.
The tendered rate for each metre of concrete kerbing shall include full compensation for the necessary excavation and preparation of bedding,
backfilling, formwork, finishing and curing of cast in situ kerbing, alternatively for procuring, furnishing and installing all materials for prefabricated
kerbing, protecting work against staining, supporting the kerbs with in situ cast concrete, and filling and pointing all construction or contraction
joints, and producing and sealing all expansion joints, all complete as specified.
All concrete shall conform to the required specification.
C3.3.2 Concrete kerbing-channeling combination:

C3.3.2.1 Prefabricated kerbing-channeling (description of type of channel and bedding with reference
to drawing)

C3.3.2.2 Cast in situ kerbing-channeling (description with reference to drawing and class of concrete
and finish indicated)
The unit of measurement shall be the metre of concrete kerbing or kerbing-channeling combination complete as constructed, measured along the
front face of the kerb.
The tendered rate for each metre of concrete kerbing and/or kerbing-channeling combination shall include full compensation for the necessary
excavation and preparation of bedding, backfilling, formwork, finishing and curing of cast in situ kerbs and channels, alternatively for procuring,
furnishing and installing all materials for prefabricated kerbing and channeling, protecting work against staining, supporting the kerbs with in situ
cast concrete, and filling and pointing all construction or contraction joints, and producing and sealing all expansion joints, all complete as specified.
C3.3.3 Extra over items C3.3.1 and C3.3.2 for concrete kerbing or concrete kerbing and
channeling on curves
C3.3.3.1 On curves of radii more than or equal to 5,0 m but less than 20 m metre (m)
C3.3.3.2 On curves with radii more than or equal to 1,0 m but less than 5,0 m metre (m)
C3.3.3.3 On curves with radii less than 1,0 m metre (m)

The unit of measurement shall be the metre of concrete kerbing or kerbing and channeling combination complete as constructed, measured along
the front face of the kerb.
The tendered rate shall include full compensation for the additional costs involved in setting out, preparing and constructing as specified on curves
with radii less than 20 m.
C3.3.4 Extra over item C3.3.2 for drop kerbs at pedestrian crossings and driveways metre (m)
The unit of measurement shall be the meter of drop kerb installed measured from the starting point where the kerb on one side starts tapering
down, across the lowered section as specified, up to the end where the kerb is at its correct level on the other side.

The tendered rate is an extra over for the extra work involved in having to excavate and construct deeper and inclined, and shall include full
compensation for all the labour, excavation, materials and backfill to complete the pedestrian crossing or driveway access as specified.
C3.3.5 Asphalt berms
C3.3.5.1 Asphalt berms placed where there are no vehicle restraint systems (drawing reference metre (m)
indicated)
C3.3.5.2 Asphalt berms placed at existing vehicle restraint systems (drawing reference indicated) metre (m)
C3.3.5.3 Prime coat (type indicated square metre (m2)
C3.3.5.4 Bond coat (type indicated) square metre (m2)
The unit of measurement for items C3.3.5.1 and C3.3.5.2 shall be the metre of asphalt berm constructed as specified.
The tendered rates shall include full compensation for procuring, furnishing, mixing and placing the material, and all other work necessary for
the completing the asphalt berms as specified
The unit of measurement for items C3.3.5.3 and C3.3.5.4 shall be the square metre of completed prime or bond coat, applied in accordance
with the specifications.
The tendered rates shall include full compensation for procuring and providing all material and for mixing and applying the prime and bond coats
complete as specified, including cleaning, compacting and trimming the surface being primed or tacked.
Payment shall be made under this item for the prime coat only if it is specified by the Engineer, and it is applied in a separate strip independently
from the prime coat of the road or shoulder surface. If prime is applied as an integral part of the prime coat of the road or shoulder surface, by
that prime coat being applied over a wider area to provide for the berms, payment for the prime shall not be made under this item, but under the
item for priming the road or shoulder.
C3.3.6 Concrete chutes (typical designs):
C3.3.6.1 Prefabricated concrete chutes (description of type with reference to drawing) metre (m)
C3.3.6.2 Cast in situ concrete chutes (description, with reference to drawing and class of concrete and metre (m)
finish indicated)
C3.3.6.3 Stone pitched chutes (description with reference to drawing and class of concrete indicated) metre (m)
The unit of measurement shall be the metre of completed chute as constructed, including any overlap, measured along the slope as constructed
but excluding transition sections and inlet and outlet structures measured separately.
The tendered rate per metre shall include full compensation for procuring, furnishing and installing the completed chutes as specified and for all
excavation and the preparation of bedding, backfilling, formwork and finishing required.
C3.3.7 Cast in situ concrete chutes (measured by components):
C3.3.7.1 Concrete (class indicated) cubic metre (m3)
C3.3.7.2 Formwork (surface finish indicated) square metre (m2)
C3.3.7.3 Stone pitched chutes
(a) Grouted stone pitching (type of chute indicated) square metre (m2)
(b) Grouted stone pitching on a concrete bed (class of concrete and type of chute indicated) square metre (m2)
Measurement and payment for formwork and concrete shall be as specified in Section A13.4 of Chapter 13. Payment for excavation trimming and
gravel or soil backfilling shall be measured and paid for separately under Section C3.1, all applicable items.
The unit of measurement for stone pitching shall be the square metre of stone pitching calculated from the drawings or as specified by the
Engineer, and shall include compensation for a concrete bed where required.
The tendered rates for stone pitching shall include full compensation for all labour, plant, material, formwork, concrete, stone and other incidentals
as may be required and specified on the drawings.

C3.3.8 Linings for open drains:
C3.3.8.1 Cast in situ concrete lining (class of concrete and type of open drain indicated) cubic metre (m3)
C3.3.8.2 ClassU2 surface finish to cast in situ concrete (type of open drain indicated) square metre (m2)
C3.3.8.3 Stone pitched lining (200 mm thickness)
(a) Grouted stone pitching (type of open drain indicated) square metre (m2)
(b) Grouted stone pitching on a concrete bed (class of concrete and type of open drain square metre (m2)
indicated)
Measurement and payment under this item shall include items for inlet, outlet, transition and similar structures.
Measurement of and payment for formwork and concrete shall be as specified in Section A13.4 of Chapter 13.
The unit of measurement for surface finish shall be the square metre of finished concrete surface. The tendered rate for surface finish shall include
full compensation for all labour, plant, material and other additional work and incidentals required for trimming the concrete lining as specified,
and curing of the concrete.
The unit of measurement for stone pitching shall be the square metre of stone pitching calculated from the drawings or as specified by the
Engineer, and shall include compensation for a concrete bed where required.
The tendered rates for stone pitching shall include full compensation for all labour, plant, material, formwork, concrete, stone and other incidentals
as may be required and specified on the drawings.
Measurement and payment for gabion linings shall be as per item C11.2.3 of Chapter 11.
C3.3.9 Formwork to cast in situ concrete lining for open drains (Class F2 surface finish):
C3.3.9.1 To sides with formwork on the internal face only square metre (m2)
C3.3.9.2 To sides with formwork on both internal and external faces (each face measured) square metre (m2)
C3.3.9.3 To ends of slabs square metre (m2)

Measurement of and payment for formwork shall be as specified in Section A13.2 of Chapter 13. Formwork under item C3.3.9.1 shall be measured
and paid for only when the side slope of the slabs exceeds 1 in 2 and the slabs cannot be constructed without formwork even when a stiff concrete
mix is used. When the Contractor elects to use precast side slabs, payment will be made for formwork as if cast in situ concrete had been used.
C3.3.10 Sealed joints in concrete and stone pitched linings of open drains (description of each metre (m)
type with reference to drawing)
The unit of measurement shall be the metre of completed joint of each type.
The tendered rate shall include full compensation for the supply of all materials and for all labour, formwork and incidentals necessary for sealing
the joint as shown on the drawings or required in the Contract Documentation.
C3.3.11 Concrete screed or backfill below chutes (thickness and class of concrete indicated) cubic metre (m3)
The unit of measurement shall be the cubic metre of concrete screed or backfill as may be specified by the Engineer to be placed below chutes.
The tendered rate shall include full compensation for furnishing, procuring and placing the concrete in screed or backfill.
C3.3.12 Reinforcement:
C3.3.12.2 High-tensile steel bars ton (t)
C3.3.12.4 Other material (specify) kilogram (kg)

Measurement and payment shall be in accordance with the provisions of item C13.3.1 of Chapter 13.
Where hot-dip galvanized steel reinforcement is indicated, the additional costs associated with the hot-dip galvanizing shall be in terms of item
C13.9.3.2 of Chapter 13.

C3.3.13 Polymer film sheeting (thickness specified) for concrete-lined open drains square metre (m2)
The unit of measurement shall be the square metre of area covered with polymer film sheeting.
The tendered rate shall include full compensation for procuring, furnishing and installing the polymer film sheeting, including wastage and overlap.
C3.3.14 Cutting bituminous surfacing and pavement layers for concrete kerbing, channeling metre (m)
or concrete-lined drains
The unit of measurement shall be the metre of bituminous surfacing and pavement layers cut where specified by the Engineer. The depth of
various layers shall not be measured separately for payment.
The tendered rate shall be regarded as an extra over to include full compensation for all labour, plant and materials required for cutting the
surfacing and pavement layers to the required depth of the kerbs, channels or drains, special excavation, and protecting and keeping the surfacing
clean, all as specified. The normal excavation and removing and disposing of the debris as required for kerb or channel installation shall be
deemed included in the normal price for such kerbs and channels, as measured elsewhere.
C3.3.15 Energy dissipaters in outlet structures
C3.3.15.1 Precast concrete blocks in outlet structures number (No)
C3.3.15.2 Stones set in outlet structures square metre (m2)

The unit of measurement for item C3.3.15.1 shall be the number of precast concrete blocks provided and installed as shown on the drawings or
The unit of measurement for item C3.3.15.2 shall be the square metre of area of outlet set in stones, as indicated on the drawings or specified by
the Engineer.
The tendered rate for energy dissipaters shall include full compensation for supplying all the materials, including concrete blocks or stones, loading,
transporting and off-loading, installing, and any other work necessary for constructing the energy dissipaters into the outlets.
C3.3.16 Demolition and removal of existing kerbs and/or channel (specify maximum size) cubic metre (m3)
The unit of measurement shall be the cubic metre of material demolished measured in situ before demolition or excavation, but including any
cementitious bedding removed with the kerbs and channels. Alternatively, the volume of debris will be calculated as 70 % of loose volume
measured in haulage vehicles.
The tendered rate shall include full compensation for breaking up the existing kerbs and/or channel to a specified maximum size, of 300 mm x
300 mm removal from site to an approved spoil site, clearing the excavation of all loose debris and to backfill the excavation where new concrete
is not required. Loading and hauling, if any, will be paid under Section C1.7 of Chapter 1.

D3.3 CONCRETE KERBING AND CHANNELING, ASPHALT BERMS,
CONTENTS
D3.3.1 SCOPE
D3.3.2 GENERAL

South Africa
COTO
Officials


CHAPTER 4: EARTHWORKS AND
PAVEMENT LAYERS: MATERIALS
October 2020

FOREWORD

Published by:

industry.
Document versions:
Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 4: EARTHWORKS AND PAVEMENT LAYERS: MATERIALS ................................................................ 1
4.1 BORROW MATERIALS ......................................................................................................................................... 1
PART A: SPECIFICATIONS ................................................................................................................................................................................. 1
PART B: LABOUR ENHANCEMENT .................................................................................................................................................................. 27
PART C: MEASUREMENT AND PAYMENT ...................................................................................................................................................... 28
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES ......................................................................................................................... 35
4.2 CUT MATERIALS ................................................................................................................................................ 36

PART A: SPECIFICATIONS ............................................................................................................................................................................... 36
4.3 EXISTING ROAD MATERIALS ........................................................................................................................... 49

4.4 COMMERCIAL MATERIALS ............................................................................................................................... 63

4.5 ALTERNATIVE MATERIALS............................................................................................................................... 78

CHAPTER 4: EARTHWORKS AND PAVEMENT LAYERS: MATERIALS
4.1 BORROW MATERIALS
CONTENTS
A4.1.1 SCOPE
A4.1.2 DEFINITIONS
A4.1.3 GENERAL
A4.1.5 MATERIALS
A4.1.8 WORKMANSHIP

A4.1 BORROW MATERIALS

A4.1.1 SCOPE
This Section covers the work requirements for sourcing natural or crushed compliant materials that can be used for the construction of earthworks
and road pavement layers from borrow pits and quarries that are developed and operated to supply materials for a specific road construction
project or projects. It contains the following specifications:
• Definitions applicable for Chapters 4 and 5.
• Responsibilities and duties of the Employer and the Contractor in providing geotechnical information, and information on the preparation
of management and utilisation plans for the borrow pits and quarries.
• The material specifications for the earthworks and road pavement layers.
• The requirements for the control, excavation, selection of material, and closure of borrow pits and quarries, as well as definitions for the
different classes of excavation.
• Producing of the road construction materials by crushing and/or screening.
• The preparation of stockpile sites and the stockpiling of materials.
Operations at quarries of commercial suppliers to produce commercial materials are excluded from the requirements in this Section A4.1, except
for the material specifications in Clause A4.1.5.
Specifications for aggregate to be used in subsoil drains, asphalt, seals, gabions and concrete are not included in this Chapter 4 but are included
in the relevant Chapters where these works are specified.
The sourcing of materials from road cuttings, box cuts and designated excavations, from existing roads, from commercial sources, and the use of
alternative materials are covered in the other Sections of this Chapter 4.
Chapter 5 – Earthworks and Pavement layers: Construction, covers the construction of the road pavement layers.
SANS test methods published by the South African Bureau of Standards (SABS) are listed in Chapter 20.
A4.1.2 DEFINITIONS
The relevant definitions in Chapter 1 shall also be applicable to this section. Additional definitions for this Section are listed below.
Borrow or sourced material - any road construction material obtained from borrow pits and quarries which is compliant for the construction of
earthworks and road pavement layers. The purpose of a borrow pit or quarry is to borrow or source or procure the material, or to win the material
as defined in the South African Minerals and Petroleum Act. Borrowing or sourcing material from borrow pits and quarries requires statutory
authorisation and approval in South Africa.
Borrow pit area or quarry area - an area clearly defined by physical boundaries, that delineate the overall area within which the sourced material
is to be excavated, stockpiled and produced.

Borrow pit - the excavated area within the borrow pit area from which road construction materials such as soil, gravel, cobbles and boulders, and
to a lesser extent hard rock, are obtained.
Crushed stone type G1 base layer - a crushed stone base layer is the uppermost (top) structural layer of a road pavement that consists of type
G1 crushed stone which:
• Is continuously graded;
• Consists of minus 37,5 mm crushed aggregate of high durability equal to that of the parent rock, low permeability because of the
continuous grading at maximum particle interlock, and low moisture sensitivity as the material is non-cohesive;
• Is compacted to a high percentage of Apparent Density; and
• Is slush-compacted to refusal or maximum particle interlock.
Deleterious minerals - minerals, when present in the natural untreated material, that are detrimental to the road pavement layers. The most
common undesirable minerals that are known to have deleterious effects in the earthworks or road pavement layers are sulfide, soluble salts and
mica:
• Sulfide is a compound of sulfur. When exposed to air and water, the sulfide decomposes easily. Oxidation leads to the development
of sulfate salts and sulfuric acid that result in acidic materials. The sulfuric acid and sulfate salts can destroy cementitious stabilising
agents, and the salts can cause blistering and cracking of a pavement.
Golden-coloured iron pyrite, also known as “fools gold”, is the most common sulfide mineral and is usually present in gold and copper
mine rocks. However, it can also occur in normal rock quarries in most other rocks. If it can be seen with the naked eye or a hand
lens it is potentially troublesome. However, in some materials it can’t be seen and other indicators such as a dark grey or black
colour in a quartzite, and white, yellow or brown staining, are indicative of sulfide in the rock.
• Soluble salts are salts that dissolve easily in water and are sufficiently soluble to cause deleterious physical or chemical effects.
Salts that generally occur in such quantities to affect the road materials are sodium chloride and sulfates.
Soluble salts can be encountered in the roadbed, the earthworks and in any of the road pavement layer materials. The dissolved
salt migrates upwards through the earthworks and road pavement layers, and is precipitated at the contact between the base layer
and the surfacing. The salt then causes the disruption of the bond between the base layer and the surfacing, and blisters develop.
This generally results in the failure of the surfacing.
• Mica of which the most striking features are its platy structure and elasticity. In this respect muscovite, the “light” or “white” mica, is
the most troublesome. The deleterious properties of mica only manifest themselves when the minerals are separated from the rock,
that is when it occurs in a loose state in weathered rock, gravel or soil (also known as free mica). The springy action of free mica,
especially muscovite, affects the compaction so that low densities and strengths are achieved. The mica plates may also prevent
filling the voids in the material, resulting in a high void ratio and a high water demand. Biotite, the “dark” or “black” mica is not as
elastic as muscovite and tends to break more easily into smaller pieces during construction. Fewer problems are experienced with
biotite. Material derived from granite, gneiss, mica schist, phyllite and some sandstones usually contain mica.
Drainage layer - the drainage layer is constructed over a wet roadbed or in the lower fill layers to provide a stable roadbed, or to intercept water
or moisture to prevent it from rising into the road prism and/or the road pavement layers.
Earthworks - all operations involved in sourcing, excavating and removing, spoil of non-compliant material, processing, hauling, importing,
depositing and placing, shaping and compacting of compliant soil, gravel, cobbles, boulders and rock. The structure resulting from these
operations may comprise a pioneer layer or a roadbed of in situ material, and fill layers. The earthwork layers form the foundation for the
subsequent road pavement layers that are constructed on top of the earthworks.
Fill layers - fill is that portion of the earthworks that is positioned above the pioneer layer or roadbed, and on which the road pavement layers are
to be constructed. Fill layers can either be sand fill, normal fill, coarse fill or rock fill materials:
• Sand fill material comprises of non-plastic sand with more than 95 % passing through the 5,0 mm sieve, and which can be
compacted to a measurable density.
• Normal fill material consists of sand, gravel, gravel with cobbles or alternative materials (refer to Section A4.5) with a maximum
particle size up to 200 mm in the fill and which can be compacted to a measurable density.
• Coarse fill material comprises gravel with cobbles, boulders, lumps of hard material or alternative materials with a maximum particle
size up to 500 mm, or a maximum particle size so that the material in the fill layer can be compacted to the specified density by the
construction equipment, whichever is the lesser. The strength of coarse fill material does not rely on mechanical interlock of the
coarse particles. Coarse fill is constructed by compaction to a measurable density or according to a compaction specification of the
number of roller-passes of applicable compaction equipment.
• Rock fill material consists predominantly of blasted or crushed angular rock with fine material filling the voids between the rock
particles to form a dense layer with minimum voids between the rocks. Rock fill may be constructed with a geotextile separation layer
between the rock fill and subsequent layers to prevent loss of material into the rock fill. The stability of rock fill results from the
mechanical interlock of the rock particles and not from the compaction of the finer material. The compacted density of a rock fill
cannot be measured.
Low volume roads - low volume roads have a maximum traffic class ES 1, that is a total of 1,0 million 80 kN single axles over 20 years..
Macadam layer - a macadam layer is a type of base layer. It consists of a single graded coarse aggregate with a filler material in the voids
between the coarse aggregate.
Material control personnel - the personnel for the control of material sourcing and stockpile operations shall be:
• A materials manager who shall be an experienced engineering geologist or engineer, a qualified senior materials technician or an
experienced senior general foreman.
• An excavation controller who shall be a materials technician or a general foreman.
• A stockpile controller who shall be an assistant materials technician or a junior foreman.

Material depth - the depth below the finished level of the road to which the material characteristics have a significant effect on the pavement
behaviour. Below this depth the strength and density of the material are assumed to have a negligible effect on the pavement, except when
conditions may arise in the subgrade that require special treatment, such as expansive materials, materials with collapsible or compressible
structures, voids or potential sinkholes, mining subsidence, slope instability, non-uniform support or the presence of deleterious minerals.
Maximum dry density (MDD) - the maximum dry density of soils and gravels is the density at the peak of the compaction curve at optimum
moisture content (OMC) as determined in accordance with test methods SANS 3001-GR30 for natural materials and SANS 3001-GR31 for
stabilised materials.
M&U Plan - a management and utilisation plan of operations for material sources to ensure that it is worked in a sustainable and sensitive manner,
that negative environmental impacts are prevented, material sourcing is optimized and that costs are minimized.
Overburden - overburden is the material immediately beneath the topsoil, if any, and above the specifically sourced material in the borrow pit,
the quarry or in the cutting. Overburden is normally not compliant for use in the construction of earthworks and pavement layers but may prove
compliant in appurtenant works such as banks (earth berms), for covering of organic material and for rehabilitation of the borrow pit or quarry.
Particle size classification - the particle size classification hereunder commonly applies for uncrushed natural material used in road construction.
Clay has a particle size smaller than 0,002 mm. It has a soapy or greasy feel when rubbed on the palm of the hand with water. Clay is shiny
when wet and stains the hands. Clay materials are plastic when wet, and coherent when dry.
Silt has a particle size larger than 0,002 mm and smaller than 0,075 mm. Silt particles are barely felt when rubbed with water on the palm of the
hand. It has a chalky feel on teeth and when dry, rubs off the hands. The individual particles cannot be seen, not even with a hand lens.
Sand is a natural untreated material that consists of particles larger than 0,075 mm and smaller than 5,0 mm but may contain a small amount of
silt and/or clay:
• Fine sand has a particle size generally between 0,075 mm and 0,3 mm. The particles are not visible to the naked eye and are just
visible under a hand lens.
• Medium sand has a particle size generally between 0,3 mm and 0,6 mm. The particles are clearly visible under a hand lens and just
visible to the naked eye.
• Coarse sand has a particle size generally between 0,6 mm and 5,0 mm. The individual particles are clearly visible to the naked eye.
Gravel is naturally occurring coarser material from weathered rock that consists mostly of rock fragments between 5,0 mm and 63 mm in size,
together with smaller varying amounts of silt, sand and/or clay.
Pebbles, cobbles and boulders are natural occurring rounded stones. Pebbles are between 5,0 mm and 63 mm in size, cobbles are larger than
63 mm and up to 200 mm, while boulders are larger than 200 mm. Core stones and floaters are large individual boulders floating within the residual
soil, or lying loose on the surface when the soil has been eroded.
Rock fragments or lumps of hard material are pieces of rock, and can be of any size and shape.
For crushed material the fraction smaller than 5,0 mm is referred to as the fine aggregate or crusher dust, while the coarse aggregate comprises
material 5,0 mm and larger.
Pavement layers - the road pavement layers comprise the base, shoulder, subbase and selected layers. Collectively the pavement layers are
the road pavement or pavement structure.
• Base layer - A layer of material constituting the uppermost (top) structural layer of a road constructed on top of other strata or layers,
and on which the surfacing will be placed. Where the shoulders of a road are surfaced and constructed with the same material as that
of the base layer, the definition for a shoulder layer shall then not be applicable as the base layer also forms the shoulder.
• Shoulder layer - The uppermost gravel unsurfaced or unsealed pavement layer lying between the outside edge of the base layer and
the shoulder breakpoint. For roads and streets with kerbing edge restraints, the shoulder layer shall be the backfill behind the kerbing.
In this instance the shoulder layer is referred to as the sidewalk layer.
• Subbase layer - The layer of material on top of the selected layers, or in the absence of selected layers on the fill, below the base,
shoulder and gravel wearing course layers, or below an asphalt base layer, paving blocks or a concrete pavement.
• Selected layer - The lower layer or layers of the pavement below the subbase layer(s) which is constructed immediately on top of the
fill, or in the absence of fill, directly on top of the roadbed.
Pioneer layer - an initial layer constructed with or without a geotextile on a soft and/or wet roadbed to provide a stable working platform for the
construction of subsequent layers.
Quarry - the excavated area within the quarry area where rock material is sourced that requires drilling and blasting.
Soil and gravel - in road construction materials that have a large proportion of fine material in comparison to the coarser material are commonly
referred to as “soil(s)”. Materials which comprise predominantly of coarser particles with a smaller amount of finer material occurring between the
larger particles, and which have good strength due to particle interlock, are described as “gravel(s)”. The grading modulus (as defined in TRH 14)
of gravel generally exceeds 1,5.
Soil constants - the soil constants of a material comprise:
• The Atterberg Liquid Limit (LL), Plastic Limit (PL), and Shrinkage Limit (SL).
• The Plasticity Index (PI).
• The Linear Shrinkage (LS) and the Linear Shrinkage Modulus (LSM = LS x % passing the 0,425 mm sieve).
Spoil material - Spoil material is excavated material that is not compliant for use anywhere in the works or is material which is surplus to the
requirements of the contract. Spoil material shall therefore be placed in borrow pits or quarries at completion or disposed of in approved spoil
sites.
Stockpile area – A prepared area designated or used for the temporary stockpiling of material until used elsewhere or placed back in the borrow
pit or quarry.
Unsuitable material – This is material in or below the roadbed of a quality that would be detrimental to the performance of the completed road,
and that must be removed. Unsuitable material can be stable or unstable.

• Stable material – This is material which have inadequate bearing strength, active (heaving) clay, material with excessive quantity of
unwanted material, and the like. Stable material can be removed or excavated efficiently by means of conventional road construction
equipment such as bulldozers, road graders, road scrapers, tractor-loader-backhoes (TLBs) or excavators. Stable material may be
taken to spoil, or to stockpile for future use depending on the material properties.
• Unstable material – This is material which cannot be removed or excavated efficiently by means of bulldozers, road graders, road
scrapers, TLBs, or excavators. The material is unstable by virtue of being soaked, such as being located in marsh or swamp conditions,
and cannot provide a stable working platform for the construction of subsequent layers. Unstable material is normally left in place and
covered with a pioneer layer but can also be removed to spoil.
Wearing course - the gravel layer constituting the uppermost (top) layer of an unsealed road. The wearing course is not considered part of the
structural layers (the base and other layers). The purpose of the wearing course is to provide a maintainable road surface which is skid resistant,
dust-free and impermeable to moisture as far as possible.
Weinert N-value - is a climatic numerical value, which has become known as the N-value. It is calculated by multiplying 12 times the computed
evaporation of the warmest month, mostly January in Southern Africa, divided by the mean annual precipitation. Four N-values are important:
• Where N is more than 10, no significant weathering profile develops, and only a thin layer of coarse gravel can generally be obtained
from the disintegrating rock.
• Where N is between 10 and 5, disintegration or the physical breakdown of all rocks is the predominant form of weathering, and a
deeper weathering profile is usually present.
• Where N is between 5 and 2, decomposition or chemical weathering or more specifically, the alteration of minerals, becomes the
predominant form of weathering of crystalline rocks. The clay component is less expansive kaolinite when derived from an acid
crystalline rock, and highly expansive montmorillionite when derived from a basic crystalline rock.
• When N drops below 2, decomposed basic crystalline rocks are still expansive. Decomposed acid crystalline rocks may become
expansive as montmorillionite may have developed from the little biotite and amphibole present.
A4.1.3 GENERAL
A4.1.3.1 Employer identified borrow pits and quarries
Borrow materials shall be obtained from sources listed and described in the Contract Documentation for which the required statutory authorisation
and approvals have been obtained by the Employer to source the materials.
The geotechnical information provided for the borrow pits and the quarries reflects the results of site investigations including the excavation of trial
pits and/or drilling, and laboratory tests conducted by or on behalf of the Employer. This information is indicative of, but not confirmation of, the
sufficiency in quantity and quality of the material. The provision of this information shall not in any way be construed as limiting the obtaining of
material from the borrow pit or quarry areas and/or to the depth of working shown on the drawings. However, borrow pits and quarries shall not
be extended beyond the limits shown on the drawings without prior written approval by the authority that authorised the use of the borrow pit or
quarry.
The decision as to which material sources the Contractor shall use at any time shall rest with the Employer or the Engineer. The Contractor shall,
at any stage of the work, use the approved source of supply that is the most compliant with regard to the quality and quantities of the various types
of available materials and the ultimate cost of the works to the Employer. The Employer shall also have the right at any stage during the
construction period to identify new borrow pits and quarries, and to have them approved by the relevant authority.
The Contractor shall be instructed by the Employer and/or the Engineer as to the applicable usage of materials, always employing the best
economic alternative (lowest construction cost in terms of tendered rates) after taking cognizance of the following:
• Quality of the material,
• Haulage distance,
• Hardness of the material, and
• Overburden removal and re-use for rehabilitation of the borrow pit.
The Contractor shall not use borrow material for any purpose other than for the execution of the contract. Material shall not be disposed of,
whether processed or not, either by sale or donation to any person without the written authorisation of the Employer.
On completion of the construction works, the Employer or his agent shall apply for a borrow pit or quarry closure certificate. The application shall
consist of the required reports compiled by or on behalf of the Employer, and the closure plan compiled by the Contractor.
A4.1.3.2 Contractor identified borrow pits and quarries

Should the Contractor during construction want to propose compliant alternative or additional borrow pits or quarries to those contained in the
Contract Documentation, the Engineer’s consent shall first be obtained prior to finalising the arrangements for the Contractor identified source.
Information to be provided shall be the reasons for the alternative or additional borrow pit or quarry, the cost and time implications, quality and
quantity of compliant material and any other information that the Engineer may require.
After obtaining the Engineer’s initial consent, the Contractor shall proceed with a detailed investigation of the borrow pit or quarry that comprises
the following activities:
• Negotiations with the landowner or legal occupant of the property about acquiring the land, compensation and conditions for entering
the property, operations at the borrow pit or quarry, and for shaping and finishing after the material has been removed. Proof must
be submitted that successful negotiations have been conducted with all the affected parties, and the landowner or legal occupant.
• An invasive geotechnical investigation of trial pitting, drilling as required, and sampling must be carried out for the intended use by
an approved geotechnical engineer, engineering geologist or an experienced road material specialist. The laboratory to be appointed
to carry out the material testing shall also be approved by the Engineer. All field work and laboratory testing shall be carried out
under the supervision of the Engineer. The scope and findings of the geotechnical investigation, material test results, quality and
quantity of the compliant material, and conditions for excavating and operating the borrow pit or quarry shall be submitted in a report
to the Engineer.

• A topographical survey of the entire borrow pit or quarry area with cadastral information shown, as well as the surveyed positions of
trial pits and boreholes.
• Obtaining the required statutory authorisation and approvals by the appropriate authorities.
The Engineer shall approve or reject the use of the alternative or additional borrow pit and/or quarry, after the results of the detailed investigation
have been received.
Where the Tenderer, during the tender stage, wishes to base the tender on alternative material source(s) to those contained in the Contract
Documentation, the alternative material source(s) shall be considered as an alternative design, for which the Engineer’s consent shall be obtained
prior to tender closure. The Engineer shall then inform the Tenderer which information of the listed activities of the detailed investigation must be
submitted with the tender, and which activities can be carried out later during construction.
Where the Contract Documentation specifies that the Contractor must identify compliant borrow pits and / or quarries, the same procedure and
requirements apply as for alternative or additional borrow pits or quarries.
The Contractor can also propose for consideration the procurement of compliant commercial materials, should they prove to be economically
viable.
The Contractor shall be responsible for all costs relating to the negotiations and compensation, the geotechnical investigation and to obtain the
statutory approvals of any alternative or additional source.
The Engineer’s approval of the Contractor identified material source shall in no way relieve the Contractor of the responsibility for the quantity and
quality of the compliant material in the source. The Engineer can at any time halt operations at the source when the material is no longer compliant
for its intended use.
After acceptance by the Employer and the Engineer of the Contractor’s identified source of material, the Engineer shall have full control of the use
of the material. The Engineer shall have authority to give instructions for excavation, producing, stockpiling, finishing and all other construction
issues.
A4.1.3.3 Negotiations with landowners or legal occupants of land

For Employer identified borrow pits, quarries, and temporary haul and access roads, the acquisition of the land and/or the removal of the material
and compensation in respect of the land, material, royalties and/or loss of crops to which the landowner or legal occupant may be entitled, will be
negotiated and paid for by the Employer. When compensation is not made directly by the Employer, payment shall be made by the Contractor
through a provisional sum in the Pricing Schedule.
The Contractor will be provided with proof of the successful negotiations and compensation, if applicable, of the Employer identified borrow pits,
quarries and temporary haul and access roads. The Contractor shall include the proof of the negotiations and compensation in the M&U plan.
The Contractor shall notify the landowner or legal occupant both verbally and in writing at least 14 calendar days before entering upon or occupying
the property. The Engineer shall be provided with a copy of such notice, together with acknowledgement of receipt by the landowner or legal
occupant. The Contractor shall not enter the property without the approval of the landowner or legal occupant.
On completion of the borrow pit or quarry operations and after the shaping and finishing activities have been carried out, the Contractor shall
obtain from the landowner or legal occupant a written statement confirming that:
• The Contractor has fulfilled all obligations under any written agreement, and
• The landowner or legal occupant is satisfied that the borrow pit, quarry and/or temporary haul and access roads have been properly
restored and are in a satisfactory condition.
All such statements shall be signed by the Contractor and the landowner or legal occupant, dated and delivered to the Engineer.
A4.1.3.4 Contractor prepared plans for borrow materials

Based on the information provided in the Contract Documentation, the Contractor shall prepare and submit a Management and Utilisation (M&U)
plan for every borrow pit and quarry, whether it be a source identified by the Employer or by the Contractor. The M&U plan shall at least show
and include the following:
• The position of a satellite office and camp site, ablution facilities, refuse disposal facilities and workshops as applicable;
• The curriculum vitae of the proposed materials manager, excavation and stockpile controllers as applicable;
• Drainage measures to keep the excavations dry and prevent water ponding;
• Demarcation of the areas for stockpiling of topsoil, overburden and the various earthworks and pavement layer materials;
• Sequence and operation of the borrow pit or quarry for sourcing the material, after the further supplementary exploration described
in Clause A4.1.7.2c);
• Method statements and risk assessments for sourcing the material and for operating the borrow pit or quarry;
• The testing protocol of the applicable tests and the frequency of testing;
• Method statements for the blasting of hard material, details for the safe storage and transport of explosives, and the process for
obtaining blasting permits in terms of the requirements of these Specifications;
• When blasting within the vicinity of buildings or structures, measures to comply with the relevant Act and Regulations pertaining to
the utilisation of explosives, as specified in Clause A1.2.7.5 of Chapter 1, proposals for the examination and recording of the condition
of the buildings and structures as specified in Clause A1.2.3.13 of Chapter 1 and compliance with the specifications given in Clause
A12.10.7.2 of Chapter 12;
• The positioning of crushers, screens and other plant for crushing and screening of materials;
• Proposed details of a closure plan at completion, including the shaping, finishing and rehabilitation of the borrow pit or quarry side
slopes and floor;
• Measures to comply with the conditions of the statutory environmental and mining approvals for the borrow pit or quarry;

• Measures to comply with the safety regulations and obligations in terms of the relevant Health and Safety Act and Regulations; and
• Procedures for regular monitoring, auditing and reporting.
M&U plans need only to be submitted during the course of the construction. However, no operations (including clearing and grubbing) at a borrow
pit or a quarry shall commence until the Contractor’s M&U plan for that material source has been reviewed and accepted by the Engineer. The
Engineer shall respond within one week after receiving an M&U plan.
The M&U plan shall be reviewed after removing of the topsoil and overburden, and revised if the sequence of excavation, type and quality of
material or any other issue requires a different operation than detailed in the original M&U plan.

A4.1.5 MATERIALS
A4.1.5.1 General
The material specifications in Clause A4.1.5 are the required specifications for the materials constructed on the road, or for the materials produced
as applicable.
The materials shall also not contain any visible materials of the following:
• Organic materials, grass and shrubs,
• Wood chippings, tree bark, and roots,
• Plastic (bags, polystyrene and so forth),
• Refuse or other non-compliant material,
• Free asbestos, or
• Any of the hazardous material listed in Clause A4.5.5.5.
The relevant test methods related to the material specifications and control thereof are listed in Clauses A20.1.3.2, A20.1.4 and A20.1.5 of
Chapter 20 with mention of special tests in Clause A20.1.6. Any ambiguity concerning the relevance and the need for additional test methods
shall be brought to the attention of the Engineer for a ruling.
SANS 3001-GR1: Wet preparation and particle size analysis, shall be mandatory and the default test method for the material grading.
SANS 3001-GR2: Dry preparation and dry particle size analysis of gravels and sands, shall only be used for the grading on clean non-plastic
sands, gravels and crushed stone for a quick indicator or where the fines are not critical.
A4.1.5.2 Grouping of Southern African road construction materials

Table A4.1.5-1 contains the grouping of rocks most frequently used for road construction.
Table A4.1.5-1: Grouping of rocks
Group Members Characteristics(1)
Amphibolite
Andesite
Anorthosite
Basalt Quartz very scarce or absent. The end products of
Diabase decomposition are clay minerals of the smectite group,
Dolerite particularly montmorillonite. These rocks are more
Basic crystalline rocks
Gabbro susceptible to decomposition than all others and require
Greenschist the most careful assessment of durability, particularly
Norite where Weinert N ≤ 5.
Peridotite
Phonolite
Serpentinite
Felsite (quartz porphyry)
Orthoclase and quartz are the two major components
Gneiss
except in syenite. The end product of decomposition is
Granite
Acid crystalline rocks kaolinite, mostly with quartz, and a smectite stage is
Pegmatite
absent. May require special attention when used where
Rhyolite
Weinert N ≤ 2.
Syenite
Chert Composed almost entirely of quartz or amorphous
Hornfels silica. Disintegration is the only mode of weathering.
High silica rocks
Quartzite These rocks are the most durable of all road building
Vein Quartz materials.
Arkose
Quartz grains in different kinds of matrix. Cementing of
Conglomerate
matrix determines largely the suitability as road building
Gritstone
Arenaceous rocks material. All members are sedimentary rocks.
Mica schist
Disintegration is the predominant form of weathering in
Quartzitic sandstone
all environments.
Sandstone

Mudstone
Phyllite Essentially rocks composed of clay minerals, often with
Argillaceous rocks Sericite schist quartz grains and occasionally with mica. The principal
Shale mode of weathering is disintegration.
Slate
Dolomite Mostly composed of calcite and/or dolomite. The rocks
Carbonate rocks Limestone weather only by disintegration or are dissolved when
Marble water is present.
Greywacke (although greywacke can
also be classified as an arenaceous
rock) Composition extremely random and is dependent on
Diamictites
Tillite the incidental mode of formation.
Volcanic tuff
Volcanic breccia
Ironstone (haematite) Material from certain mining operations. Durable

Metallic ores (mining material) Magnesite materials which disintegrate in most cases when
Magnetite weathering.
Calcrete Secondarily in place cemented and/or replaced soils

Pedogenic materials Ferricrete / laterite with strongest materials on top of the succession. Host
Silcrete soil and cementing material, besides strength,
Gypcrete determine the road building properties.
Note:
(1)
Reference is made to TRH14 Appendix A that contains useful information on the properties of the rock groups and the identification
thereof.
A4.1.5.3 Pioneer layer

Material for a pioneer layer shall consist of one of the following:
• Predominantly blasted rock and boulders (shape not completely rounded or polished), generally in the size range 100 mm to 500
mm, and a lack of material finer than 50 mm.
• Coarse sand with a plasticity index less than 6.
• Alternative materials comprising concrete, concrete bricks and hard burnt clay bricks sourced from construction and demolition of
structures. The materials shall be selected or crushed to be also generally in the size range 100 mm to 500 mm, with
a lack of material finer than 50 mm.
Material for a pioneer layer does not have to conform to gradation or shape requirements, except for boulders as specified above.
A4.1.5.4 Sand, normal and coarse fill material in the earthworks layers
Compliant sand fill shall have a CBR ≥ 7 % and a swell ≤ 1 % at 100 % of MDD.
The CBR of compliant normal and coarse fill shall comply with the requirements in Table A4.1.5-2.
Table A4.1.5-2: Requirements for normal and coarse fill
Position of the roadbed below the final road surface CBR and swell
Within the material depth of: ● 1 200 mm for freeways, major interurban roads, rural
and urban arterials. (Class 1/Category A roads).
● 1 000 mm for interurban collectors, major rural roads,
major commercial roads, urban arterials. (Class 2/
Category B roads).
CBR ≥ 7 % at 93 % of MDD.
● 800 mm for lightly trafficked rural and urban collector
Swell ≤ 2 % at 100 % of MDD.
and distributor roads, bus routes and commercial
roads. (Class 3 and 4/Category C roads).
● 600 mm for low volume roads, rural local roads, and
urban local residential streets carrying few heavy
vehicles. (Class 5/Category D roads).
CBR ≥ 3 % at 93 % of MDD.
Below the applicable material depth up to 10 m.
Swell ≤ 2 % at 100 % of MDD.
To be specified in the Contract

Documentation, as per the design by
an experienced geotechnical engineer
More than 10 m. of the fill slope, settlement and
consolidation, the fill toe protection and
drains, the foundation stability and any
other design issues.
The normal and coarse fill materials may contain inactive clay and silt, provided that the CBR strength requirements are complied with.

A4.1.5.5 Rock fill material in the earthworks layers
Rock fill material shall have a maximum dimension not exceeding 500 mm.
The following rock types that decompose or deteriorate rapidly on exposure to air and moisture shall not be used unless permitted in the Contract
Documentation:
• Mudrocks and soft or weathered shales.
• Highly weathered, very soft basic crystalline rocks in the wet eastern part of Southern Africa where Weinert N ≤ 5.
• Highly weathered (brown coloured) tillite.
Rock fill that is deficient in fine material can be used in the works, provided that after placing the rock fill and during the compaction, concrete or
plaster sand or non-parent (not from the same source as the rock) sandy material, is spread uniformly over the surface of the rock fill and vibrated
or worked into and between the rocks to fill the voids. The grading of the sand shall be such that all material passes the 5,0 mm sieve and not
more than 15 % shall pass the 0,075 mm sieve.
A strength requirement such as the CBR is not required for rock fill material.
A4.1.5.6 Requirements for types G7 to G9 materials for the pavement layers

Gravel-soil types G7 to G9 materials shall be classified according to the requirements in Table A4.1.5-3.
Table A4.1.5-3: Requirements for types G7 to G9 materials
Type of material
Property
G7 G8 G9
Soil, gravel with cobbles, boulders

and lumps of hard material that may
DESCRIPTION OF MATERIAL Soil, gravel, or alternative materials.
require crushing or grid rolling, or
alternative materials.
(i) Uncrushed material: Two-

thirds of the compacted layer
MAXIMUM PARTICLE SIZE thickness. Two-thirds of the compacted layer thickness.
(ii) Crushed material: 100 mm.
GRADING MODULUS (GM) 0,75 – 2,7.
All materials
SOIL CONSTANTS except PI ≤ (3xGM) + 10.
ON THE P0,425 calcrete
FRACTION (= % passing
the 0,425 mm sieve)
Calcrete PI ≤ 20.
STRENGTH (CBR at % of MDD) CBR ≥ 15 % at 93 %.(1) CBR ≥ 10 % at 93 %. CBR ≥ 7 % at 93 %.
SWELL AT 100 % OF MDD Swell ≤ 1,5 %.
No requirement, except when mudstone or shale is used in the selected layer.

DURABILITY
Requirements then as specified in Clause A4.1.5.16.
DELETERIOUS MINERALS Specified in Clause A4.1.5.17.
Note:
(1)
The minimum CBR requirement shall be increased to 18 % at 93 % of MDD for an otherwise compliant G7 material that requires modification
such as lime treatment or mechanical modification to bring the CBR within specification.

Gravel, natural occurring or modified or processed, types G4 to G6 materials shall be classified according to the requirements in the
Table A4.1.5-4.
Table A4.1.5-4: Requirements for types G4 to G6 materials
Type of material
Property
G4A G4B G5A G5B G6
1. Gravel with pebbles and small 1. Gravel with pebbles
cobbles, or gravel with larger and small cobbles, or
cobbles, boulders and lumps of gravel with larger
hard material, or soft rock that cobbles, boulders and
require single- or two-stage Medium to hard rock, or lumps of hard material,
Medium to hard rock, or Gravel with cobbles,
crushing, or grid rolling. boulders that require multi- or soft rock that require
DESCRIPTION OF MATERIAL boulders that require multi- or alternative
stage crushing and single- or two-stage
stage crushing and screening. materials.
2. Pedogenic materials that require screening. crushing, or grid rolling.
dozer ripping.
2. Pedogenic materials
that require dozer
ripping.
1. In a base layer: 50 mm. 1. In a base layer: 50 mm.
2. In a stabilised subbase 2. In a stabilised subbase layer: 63 mm.

layer: 63 mm.
MAXIMUM PARTICLE SIZE 50 mm. 50 mm. 3. In all other pavement layers: Two-thirds of the
3. In all other pavement
compacted layer thickness, or 100 mm
layers: Two-thirds of the
whichever is the smaller.
compacted layer
thickness, or 100 mm
whichever is the smaller.
Flakiness Index ≤ 35 on all Flakiness Index ≤ 35 on all

FLAKINESS INDEX individual fractions above None specified. individual fractions above None specified.
14 mm. 14 mm.
Gravels and boulders that are Gravels and boulders

crushed: at least 50 % by mass of that are crushed: at least
the material retained on each of the 50 % by mass of the
FRACTURED FACES 5 mm and larger sieves shall have material retained on
None specified. None specified. None specified.
at least one fractured face. each of the 5 mm and
larger sieves shall have
at least one fractured
face.
Percentage passing sieve, Percentage passing sieve,
Sieve size (mm)
by mass by mass
50 100 100
37,5 85 – 100 85 – 100
20 61 – 91 61 – 91
GRADING
14 48 – 82 None specified. 48 – 82 None specified.
ENVELOPE
5 31 – 66 31 – 66
2 20 – 50 20 – 50
0,425 10 – 30 10 – 30
0,075 5 – 15 5 – 15
GRADING MODULUS (GM) None specified 1,75 (base) / 1,5 (subbase) – 2,5. None specified 1,75 (base) / 1,5 (subbase) – 2,5.
(a) All materials except calcrete: (a) All materials except calcrete: (a) All materials
LL ≤ 25. LL ≤ 30. except calcrete:
PI ≤ 6. PI ≤ 10. PI ≤ 2GM + 10.
LS ≤ 3 %. LS ≤ 5 %. LS ≤ 7 %.
SOIL CONSTANTS ON THE (b) Calcrete: (b) Calcrete: (b) Calcrete:
P0,425 FRACTION(1) LL  30. LL  45. LL ≤ 45.
(= % passing the 0.425 mm sieve) PI  8. PI  15. PI ≤ 15.
LSM  170. LS  6 %. LS  6 %, or
LSM  320. LSM ≤ 320, whichever
is the more stringent
requirement.
CBR ≥ 45 % at 95 %.
STRENGTH (CBR at % of MDD) Except In the dry western parts of Southern Africa
CBR ≥ 80 % at 100 %. (Weinert N ≥ 10) and when the E80s < 3 million, then CBR ≥ 25 % at 95 %.
the subbase CBR ≥ 25 % at 95 % provided that
the base thickness ≥ 150 mm.
SWELL AT 100 % OF MDD Swell ≤ 0,2 %. Swell ≤ 0,5 %. Swell ≤ 0,5 %.
DURABILITY Specified in Clause A4.1.5.16.
Note:
(1)
The LS and the LSM shall be the primary soil constants for acceptance control of calcrete, and the PI for all other materials.

Graded crushed stone types G1 to G3 materials shall be classified according to the requirements in Table A4.1.5-5.
Table A4.1.5-5: Requirements for types G1 to G3 crushed stone
Type of material
Property
G1 G2 G3
Sound(1), clean(2), unweathered(3) Sound(1), clean(2) rock and Sound(1), rock and boulders, or
PARENT MATERIAL
high quality rock. boulders. coarse gravel.
Only fines crushed from the same May contain up to 10 % by mass May contain up to 15 % by mass of
sound parent rock may be added for of approved natural fines not approved natural fines not obtained
grading correction provided that added necessarily obtained from the from the same parent rock. Added
ADDITIONAL FINES
fines shall have a LL ≤ 25 and a PI ≤ 4. same parent rock. Added fines fines shall have a LL ≤ 25 and a
The quantity of fines shall not exceed shall have a LL ≤ 25 and a PI ≤ 6.
10 % by mass. PI ≤ 6.
10 % Fines Aggregate Crushing Value (10 % FACT) and Aggregate Crushing Value (ACV)
AGGREGATE STRENGTH
specified in table A4.1.5-6
FLAKINESS INDEX Flakiness index ≤ 35 on all individual fractions above 14 mm.
For crushed materials at least 50 % by mass of the individual fractions
FRACTURED FACES All faces shall be fractured faces. retained on each standard sieve 5 mm and larger shall have at least one
fractured face.
(a) All materials except calcrete:
LL ≤ 25.
Fraction E80s > 15 million E80s ≤ 15 million PI ≤ 6.
smaller than LL ≤ 25. LS ≤ 3 %.
SOIL PI ≤ 6.
LS ≤ 3 %. (b) Calcrete:
CONSTANTS
LL ≤ 25. LL ≤ 30.
0,425 mm PI = NP. PI ≤ 4. PI ≤ 8.
LS ≤ 2 %. LSM ≤ 170.
0,075 mm PI ≤ 8 PI ≤ 12 PI ≤ 12.
MAXIMUM PARTICLE SIZE 37,5 mm 37,5 mm 28 mm
Sieve Percentage passing sieve, by

Percentage passing sieve, by mass Percentage passing sieve, by mass
size(mm) mass
37,5 100 100 100 ----

28 86 – 90 86 – 95 86 – 95 100
20 73 – 80 73 – 86 73 – 86 87 – 96
GRADING
ENVELOPE(4) 14 61 – 71 61 – 76 61 – 76 73 – 86
5 37 – 49 37 – 54 37 – 54 43 – 61
2 23 – 36 23 – 40 23 – 40 27 – 45
0,425 11 – 20 11 – 24 11 – 24 13 – 27
0,075 4 – 10 4 – 12 4 – 12 5 - 12
STRENGTH (CBR at % of
None specified. CBR ≥ 80 % at 100 %.
MDD)
SWELL AT 100 % OF MDD None specified. Swell ≤ 0,2 %.
DURABILITY Specified in Clause A4.1.5.16.
Notes:
(1)
Sound – adequate strength and durability.
(2)
Clean – Free from visible traces of materials not from the parent rock.
(3)
Unweathered – Fresh or faintly weathered rock with no visible signs under the naked eye of alteration in the rock material, but discontinuity
planes or surfaces may be stained or discoloured.
(4)
The grading lines, when plotted to log scale, shall confirm a continuous particle size distribution within the grading envelope, without any
abrupt directional changes or meandering.
Crushed stone for G1 and G2 material shall not be processed from the following rock groups:
• Arenaceous rocks except quartzitic sandstone.
• Argillaceous rocks.
• Pedogenic materials, including calcrete.

The aggregate strength requirements, namely the 10 % fines aggregate (10 % FACT) and the aggregate crushing (ACV) limiting values, for the
types G1 to G3 materials are given in Table A4.1.5-6.
Table A4.1.5-6: Requirements for 10 % FACT and ACV values(1)
10 % FACT ACV
Rock group
(dry) (maximum)
(minimum)
Arenaceous rocks with a siliceous cementing

110 kN 29 %
matrix (quartzitic sandstone)
Arenaceous rocks with non-siliceous material 140 kN 27 %
Diamictites 200 kN 21 %
Calcrete 80 kN 29 %
All other compliant rock groups 110 kN 29 %
Note:
(1)
When there is a contradiction between the 10 % FACT and the ACV test results about the acceptance of the material, the Engineer shall
instruct whether the material shall be evaluated for acceptance on the 10 % FACT or on the ACV test results.
A4.1.5.9 Sand in fill and pavement layers of sealed low volume roads
Natural untreated sand in the fill and pavement layers of sealed low volume roads shall comply with the requirements in Table A4.1.5-7.
Table A4.1.5-7: Requirements for natural untreated sand in sealed low volume road layers(1)
Property Base and shoulder(2) Subbase Selected Fill
% Passing 2 mm 95 – 100
% Passing 0,075 mm (P0,075) 5 – 20
Grading modulus 0,75 – 1,50 None specified
PI on 0,075 mm fraction (PI0,075) SP – 25
P0,075 x PI0,075 25 – 300
Soaked CBR ≥ 50 % CBR ≥ 30 % CBR ≥ 15 % CBR ≥ 7 %

Strength (CBR at
100 % of MDD)(3)
Unsoaked CBR ≥ 60 % None specified
Swell at 100 % of MDD Swell ≤ 0,1 %

Notes:
(1)
In the drier western part of Southern Africa and when a choice can be made between different colour sands, then only yellowish-brown to red
sand shall be used while white or grey sand shall be avoided. It is also advantageous due to cementation, for the sand to contain at least
0,3 % Fe or 1,2 % Fe2O3 as determined by CBD (citrate-bicarbonate-dithionite) or XRF (X-ray fluorescence) analysis respectively. Natural
untreated sand may only be used in the base layer and unsealed shoulder on low volume roads in the dry western parts of Southern Africa where
Weinert N ≥ 10, and where the E80 traffic is less than 0,3 million.
(2)
Natural untreated sand may only be used in the base layer and unsealed shoulder on low volume roads in the dry western parts of Southern
Africa where Weinert N ≥ 10, and where the E80 traffic is less than 0,3 million.
(3)
The layer strengths shall also comply with the DCP-DN pavement design values when specified in the Contract Documentation.

A4.1.5.10 Macadam materials
a) Coarse aggregate
Coarse aggregate in a macadam layer shall be obtained from the crushing of sound unweathered rock (refer Clause A4.1.5.8 for definitions), and shall
comply with the requirements in Table A4.1.5-8.
Table A4.1.5-8: Requirements for coarse aggregate in a macadam layer
Property Requirement
ACV ≤ 29 %, or
STRENGTH(1) 10 % FACT (dry) ≥ 100 kN and the
wet/dry ratio ≥ 75 %
MAXIMUM PARTICLE SIZE 63 mm 50 mm 37,5 mm
Flakiness Index ≤ 35 on the Flakiness Index ≤ 35 on the Flakiness Index ≤ 35 on the

FLAKINESS INDEX
-50 mm and +37,5 mm fraction -37,5 mm and +28 mm fraction -28 mm and +20 mm fraction
Sieve
Percentage passing by mass Percentage passing by mass Percentage passing by mass
size(mm)
63 100 --- ---
50 85 – 100 100 ---

GRADING
ENVELOPE 37,5 0 – 30 85 – 100 100
28 0–5 0 – 50 85 –100
20 0 0 – 25 0 – 30
14 0 0-5 0-5
Note:
(1)
When there is a contradiction between the 10 % FACT and the ACV results about the acceptance of the material, the Engineer shall instruct
whether the material shall be evaluated for acceptance on the 10 % FACT or on the ACV test results.
b) Fine aggregate
The fine aggregate in a dry-bound, waterbound or penetration macadam layer shall comply with the requirements in Table A4.1.5-9.
Table A4.1.5-9: Requirements for fine aggregate in a macadam layer
Percentage passing
Sieve size (mm)
by mass
GRADING 7,1 100

ENVELOPE
5 85 – 100
0,075 10 – 20
LL ≤ 25
SOIL CONSTANTS ON THE P0,425
FRACTION (= % passing the 0,425 mm PI ≤ 6
sieve)
LS ≤ 3 %
c) Slurrybound macadam aggregate
The slurry material for a slurrybound macadam is covered in Chapter 10: Surface Treatments.

A4.1.5.11 Unsealed shoulder material
The material for the unsealed shoulder of a sealed or surfaced road where the shoulders are not constructed with the same material as the base
layer shall comply with the requirements in Table A4.1.5-10.
Table A4.1.5-10: Requirements for material of an unsealed shoulder
Natural gravel or crushed material

Description of material Calcrete
except calcrete
Maximum particle size 100 mm
Grading modulus (GM) 1,5 – 2,5
SOIL CONSTANTS LL Not specified LL ≤ 45

ON THE P0,425
FRACTION PI 6 minimum up to (3xGM + 10) PI ≤ 15
(= % passing the
0,425mm sieve) LSM Not specified LSM ≤ 320
Aggregate finger value (AFV) Not specified ≥ 60 %
Aggregate plier value (APV) Not specified ≥ 20 %
Strength (CBR at % of MDD) CBR ≥ 45 % at 95 %
Swell at 100 % of MDD Swell ≤ 0,5 %
10 % FACT (dry) ≥ 50 kN None specified
Sand shall not be used for untreated shoulder material due to its high erodibility, except for low volume roads in dry areas (Weinert
N ≥ 10), and it shall also not be used when the sand does not conform to the base layer sand specification in Table A4.1.5-7.
A4.1.5.12 Wearing course gravel material

Gravel material other than calcrete for the wearing course of an unsealed road shall comply with the requirements in Table A4.1.5-11.
Table A4.1.5-11: Requirements for gravel wearing course material other than calcrete(1)
Requirement
Property Mine or forest haul roads
Rural and urban roads
for heavy vehicles
Description of material Natural gravel or crushed material except calcrete
Maximum particle size 37,5 mm 50 mm
Oversize index (l0) N/A ≤ 5%
Grading coefficient (Gc) 15 – 35 20 – 35
Shrinkage product (Sp) 100 – 240 100 – 240
PI on the P0,425 fraction 6 – 12 6 - 12
Strength (CBR at % of MDD) CBR ≥ 15 % at 95 % CBR ≥ 25 % at 95 %
Treton impact value 20 % – 65 % 20 % – 65 %
Io = Percent retained on 37,5 mm sieve.

Gc = (Percent passing 28 mm sieve – percent passing 2,0 mm sieve) x percent passing 5,0 mm sieve/100.
Sp = Linear shrinkage x percent passing 0,425 mm sieve.
Note:
(1)
Sand alone shall not be compliant as a wearing course, except for very low volume roads and when the sand complies with the base
layer specification in Table A4.1.5-7.
Calcrete material for the wearing course of unsealed rural and urban roads shall comply with requirements in Table A4.1.5-12.

Table A4.1.5-12: Requirements for calcrete wearing course material
Percentage passing 0,425 mm sieve, by mass

Property
20 – 40 41 - 50 51 - 60 61 - 75
MAXIMUM PARTICLE SIZE 37,5 mm
LL 30 - 65 22 - 48 20 - 40 18 - 36
SOIL CONSTANTS ON THE

PI 9 - 22 7 - 23 5 - 13 8 - 13
P0,425 FRACTION
(= % passing the 0,425 mm
LS 2,0 – 9,5(1) 2,7 – 9,0 2,0 – 5,5 2,0 -5,0
sieve)
LSM 70 – 340(2) 130 – 395 100 – 320 130 - 330
AGGREGATE FINGER VALUE (AFV) ≥ 65 % ≥ 60 % ≥ 40 % ≥ 35 %
AGGREGATE PLIER VALUE (APV) ≥ 20 % ≥ 20 %(3) ≥ 15 % None specified
Notes:
(1)
LS between 2,0 and 2,6 may cause slight looseness and dust.
(2)
LSM between 70 and 100 may cause slight looseness and dust.
(3)
A minimum APV of 14 % is permissible if the AFV ≥ 75 %.
A4.1.5.13 Drainage layer material

a) Drainage blanket layer material
Material for a drainage blanket layer comprising coarse material shall comply with the gradation requirements in Table A4.1.5-13.
Table A4.1.5-13: Gradation of material for a drainage blanket layer
Percentage passing sieve,

Sieve size (mm)
by mass
50 100
37,5 74 – 100
28 56 – 98
14 42 – 69
5 25 – 37
2 15 – 20
0,425 4–9
0,075 0–4
b) Sand filter material

Sand for filter material in the fill layers shall be clean, durable sand and shall comply with the gradation requirements in Table A4.1.5-14.
Table A4.1.5-14: Gradation of sand filter material
Percentage passing sieve,

by mass
Sieve size (mm)
Natural Crusher
sand sand
5 90 – 100
0,150 5 – 25
0,075 0–5 0 – 10

A4.1.5.14 Soil cement in the pavement layers
Soil cement, also known as soilcrete, may be used in widenings that cannot be constructed efficiently by conventional road construction equipment,
or for the backfill of existing manholes and similar structures, and services within the road prism. It shall consist of a wet or stiff mixture of crushed
or gravel material with cement. The crushed or gravel material shall be of at least subbase quality material, with a maximum particle size of
37,5 mm and a PI not exceeding 10. When mixed on the site, the soil cement shall either be:
• A wet mixture containing 5 % cement by mass or 100 kg (2 bags) of cement per 1,0 m³ of material and sufficient water for it to be compacted
with concrete vibrators, or
• A stiff mixture containing 3 % cement by mass or 100 kg (2 bags) of cement per 1,5 m³ of material and just sufficient water for it to be placed
in layers and compacted to a measurable density with applicable compaction equipment.
Where soil cement is provided by commercial suppliers, the 7-day concrete cube strength of the soil cement shall not exceed 7 MPa.
A4.1.5.15 Emulsion treated base material

Emulsion treated base material, also known as ETB, for use in patches, narrow widenings and in new base layers where light construction
equipment is used or where a crushed stone base layer cannot be constructed, shall consist of the following mix components:
• Crushed stone type G1 or G2 material: 1,0 cubic metre compacted material.
• Cement: 1 % by mass or 25 kg (half a bag) per cubic metre crushed stone material.
• Anionic emulsion: 3 % by mass or 66 litre (one-third of a 200 litre drum) per cubic metre crushed stone material.
• Water for compaction as required.
When instructed by the Engineer the ITS of the ETB shall be verified for compliance with that specified for a BSM2 in Section A4.4,
Table A4.4.5-3. If the ITS requirement is not achieved, the above mix design shall be redesigned until the ETB complies with the ITS specification.
A4.1.5.16 Durability of materials

a) Requirements for crushed stone materials in the base and subbase layers
Crushed stone material types G1 to G5A, when used in the base and subbase layers, shall comply with the requirements hereunder.
(i) Basic crystalline rocks
Decomposition of the primary minerals into montmorillionite is the predominant form of weathering.
There is no single basic crystalline aggregate characteristic that can be used to fully determine the suitability of the aggregate. The
suite of tests in Table A4.1.5-15 shall be carried out and if any result is outside the specification, the material shall be regarded with
caution. The material shall then be further evaluated and declared fit for use by an experienced engineering geologist or a road
materials specialist.
Table A4.1.5-15: Durability tests and requirements for basic crystalline rocks
Requirement
Test (1)
Base material Subbase material
1. 10 % FACT(2) value after soaking in ethylene glycol for 1 day,
≥ 80 % ≥ 70 %
compared to the dry value
5 days soaking EGDI < 10 EGDI < 15
2. Ethylene Glycol Durabilty Index
(EGDI) 20 day : 5 day Ratio < 1,5
None specified
soaking ratio if 20 day EGDI > 10
2. Durability mill test (dry material test):
2.1 Index ≤ 80 ≤ 125
2.2 Percentage passing 0,425 mm after the test None specified ≤ 35
2. Product of maximum increase in PI and maximum increase in
≤7 None specified
P0,425 mm, between the DMIdry and the DMIglycol soaked for 5 days (3)
3. Smectite content using the Spot Counting(4) and/or the Rietveld

≤5% None specified
quantitative XRD (X-ray diffraction) tests
3. Percentage secondary minerals as in the publication “The natural road Durability lines in Table 11 on page 95
construction materials of Southern Africa”, by HH Weinert of the publication
Notes:
(1)
Tests to be carried out in sequence of numbering. Results in a set to be assessed, thereafter samples that fall way
below (or above) the limiting values shall be disqualified without further testing.
(2)
i) 10 % FACT can be estimated from the Aggregate Impact Value (AIV) (test method BS 812-112:1990):
10 % FACT = 10(2,915 – 0,03AIV)
ii) After soaking, rinse aggregates with water followed by immediate towel drying and air drying at temperatures not exceeding
70 °C.
(3)
i) Gradings of samples shall be identical.
ii) Soaking only of material retained on the 2,0 mm sieve.
iii) After soaking, rinse and dry material as for 10 % FACT.
(4)
Spot Counting test to be carried out by an experienced geologist.
In areas where Weinert N ≤ 2, all crushed stone bases to be constructed with material derived from basic crystalline rocks
shall be treated with lime, irrespective of the smectite content.

(ii) All other rocks
Disintegration of all rocks is the predominant form of weathering, and the durability of compliant crushed rocks shall comply with the
requirements in Table A4.1.5-16.
Table A4.1.5-16: Durability requirements for all other rocks

Durability Mill test
10 % FACT
Rock group Wet / Dry ratio(1) % passing 0,425 mm
Index
sieve after the test
(minimum) (maximum)
(maximum)
Acid crystalline, high silica and

75 420 35
carbonate rocks
Arenaceous rocks with a

siliceous cementing matrix 75 125 35
(quartzitic sandstone)
Arenaceous rocks with non-

siliceous material (not to be use 75 125 35
for types G1 and G2 material))
Diamictites 70 125 35
Calcrete 60 480 40
Notes:
(1)
Materials with a 10 % FACT wet to dry ratio of less than the minimum ratio, except for calcrete, may be used, provided that the
soaked value is equal to or more than the specified dry limit in Table A4.1.5-6.
b) Requirements for mudrock (mudstone and shale)

The durability of mudrock used in the road pavement layers shall comply with the requirements in Table A4.1.5-17.
Table A4.1.5-17: Durability requirements for mudrock used in the road pavement layers
10 % FACT (wet)
Material type Soundness test class
(minimum)
G5B 90 kN I or II
G6 80 kN I or II
G7, G8 and G9 60 kN I, II or III
Mudrock shall not be used for material types G3 to G5A, unless approved by an experienced road materials specialist.
A4.1.5.17 Deleterious minerals

a) Sulfide minerals
Material with a pH less than 6 and a total sulphur content of more than 0,1 % by mass shall be evaluated and recommended fit for use with
precautionary measures by an experienced road materials specialist.
b) Soluble salts, acids and sulfates
The total soluble salt, acid and sulfate contents of the natural or untreated material in the road pavement layers (crushed stone or gravel) shall
comply with the requirements in Table A4.1.5-18. Both the electric conductivity and the pH tests shall be carried out on the soil paste.
Table A4.1.5-18: Requirements for total soluble salts, acids and sulfates
Test Limiting value for use without precautionary
Deleterious mineral
measures or treatment of the material
Electric conductivity of fine aggregate Base and subbase layers: ≤ 0,15 (≤ 0,10)(1)
Total soluble salts (Siemens/metre) (S/m) Selected layers: ≤ 0,40 (0,20)(1)(2)
Acids pH ≥ 6,0
Crushed stone material: ≤ 0,05 %

Acid-soluble sulfate content
Sulfates (calculated as SO3) For material to be stabilized: ≤ 0,25 %
Water-soluble sulfate content For material to be stabilised: ≤ 0,25 % (≤ 2,5 mg/l)

Notes:
(1)
Value in brackets applicable in areas of poor drainage such as with high or perched water tables, unlined side drains and seepage in cuttings.
(2)
Where the EC > 0,20 S/m the selected layer shall be covered by the next layer within 14 days.
When the sulfate content is compliant but either or both of the EC and/or the pH do not comply with the requirements, then:
• The material can be used where the EC is compliant but the pH < 6,0, provided that it is treated with lime until the pH ≥ 10.
• Base and subbase material with the EC > 0,15 S/m can be used, provided that the pH of the material is within specification or treated with
lime to specification, if required, and that precautionary measures are prescribed by an experienced road materials specialist.
• Where the material is not compliant on both the EC and pH evaluations, the material shall only be considered for use by the Engineer when
it has been evaluated and the material has been recommended fit for use by an experienced engineering geologist or road materials
specialist.
c) Micas
Crushed stone base aggregates shall not contain more than 2 % by mass of free mica, especially muscovite, when assessed by visually separating
the particles, or more than 4 % by volume when assessed by means of microscopic slides. Other road pavement material that contains free mica
that can be detected with the naked eye shall not be used, unless its durability (density reduction, CBR and/or ITS strengths and wet-dry durability)
has been evaluated and the material has been recommended fit for use by an experienced engineering geologist or road materials specialist.
A4.1.5.18 Water in construction

Water to be used for the construction of the earthworks and road pavement layers, including for bituminous stabilisation, shall comply with the
Table A4.1.5-19: Construction water for earthworks and pavement layers
Electric Conductivity Total dissolved
pH range at Sulfate as SO4
Purpose (EC) at 25°C solids (TDS)
25°C (maximum)
(maximum) (maximum)
1. Crushed stone base layer compaction 1200 mg/l

170 mS/m 5,0 – 9,7 -
and slush – compaction
2. Chemical stabilisation compaction

170 mS/m 1200 mg/l 5,0 – 9,7 450 mg/l
and curing
3. Bituminous stabilisation 170 mS/m 1200 mg/l 5,0 – 9,7 -
4. Other layers and materials 370 mS/m 2400 mg/l 4,0 – 10,0 -
Note:
(1)
Siemens per metre (S/m) is the standard SI unit. The salinity of water can also be expressed in milligram per litre (mg/ℓ) or percentage (%). The
relationships between the units are: 1 000 mg/ℓ = 0,1 % = 150 mS/m.
Purified waste water, also known as effluent, and water from other sources that may contain visible quantities of physical and aesthetical, chemical
or organic determinants expected to have a detrimental effect on the road layers, can be considered for the construction of the earthworks and
the road pavement layers, provided that it complies with the requirements in the above table. In addition, for chemical stabilised layers, the
stabilised material shall comply with the strength requirements for UCS and ITS at extended 28-day curing periods and the durability (WDD)
requirements specified in Table A4.4.5-2. Water containing raw sewage shall not be used anywhere in the construction.
The use of brackish water and sea water can be considered for the compaction, provided that the saline water shall be used instead of the
prescribed distilled water in the pH and EC tests and that the requirements for soluble salts in Table A4.1.5-18 shall not be exceeded, except with
recommendations by an experienced road materials specialist and proved in a trial experimental section. Brackish water and seawater shall not
be used for the curing of any stabilised layer.
Turbid water can be used for compaction without further testing in addition to the tests specified in Table A4.1.5-19, except for crushed stone
bases where strict requirements for the PI and the P0,075 apply. In this instance, a sample shall be prepared of the crushed stone material mixed
with the required quantity of turbid water to reach optimum moisture content. After drying out of the material, the PI and P0,075 shall be tested
and evaluated for compliance with the specified limits in Table A4.1.5-5.
Effluent, brackish water and sea water shall not be used for bituminous stabilisation or for diluting a bitumen emulsion, unless the use of the water
has been approved in writing by the supplier.
A4.1.5.19 Quality of materials

It is the Contractor’s responsibility to ensure that the material constructed on the road shall comply with the material specifications, subject to the
relevant provisions of the Contract Documentation. The Contractor’s process control testing shall also include the monitoring of the quality and
quantity of material excavated in the borrow pits and quarries and placed in the stockpiles.
When it is a contract for producing only materials without any construction, such as for the producing of materials for multiple existing or future
projects, the material in stockpile shall comply with the material specifications.
Where the Employer provides materials that have been produced and stockpiled by other Contractors or suppliers, it will still be the Contractor’s
responsibility to ensure that the materials comply with the material specifications for the contract. Where it can be proved that the actual quality
of the material is different from that provided at tender stage, or if the material in the stockpile has changed over time to the point where it no
longer complies with the specifications, the material shall not be used in the road works unless the Employer confirms in writing that the material
may be used.
Based on a visual inspection by the Engineer and on the results of material tests as deemed appropriate to check compliance with the
specifications, the Engineer shall have the right to declare the material non-compliant for use at any time before construction on the road or
stockpiling as applicable. The Contractor shall then submit proposals for acceptance by the Engineer to rectify or replace the non-compliant
material. Acceptance control testing of materials by the Engineer shall only be carried out during or after construction on the road, or of the material
in the stockpile as applicable.

Construction equipment to source the borrow materials shall comply with the requirements of Clause A1.2.6 of Chapter 1.
Planned layouts of the appropriate fixed (static) or combined interlinked mobile plants for crushing and screening material provided by the
Contractor shall show the configuration of the crushers, screening and separation plants based on the prevailing rock material and on the required
material types to be produced.
Crushing plants shall be subject to the requirements of the applicable industrial legislation that governs noise, gas and dust emissions into the
atmosphere. Particular attention shall be given to the impact that the siting of crushing plants will have on the nearby built environment.

A4.1.7.1 Haul and access roads
a) Existing roads and streets
The Contractor will be entitled to use existing public roads and municipal streets, subject to any constraint on axle load legislated or imposed by
the road authority. The Contractor shall be acquainted with any restrictions about the road width, overhead clearance at structures and services,
and maximum allowable axle loads.
Where the surfacing of a road or street to be used for hauling is already in a visual poor condition or when it is expected that it will deteriorate
considerably during the hauling, the Contractor in conjunction with the Engineer shall conduct a visual assessment and compile a photographic
record of the road or street’s condition for record purposes before hauling any construction material over the road or street.
The Contractor shall handle all claims by the road authority regarding any damage caused by the Contractor’s vehicles and/or equipment.
The Contractor will not be required to maintain existing roads and streets belonging to other authorities that is used to haul material or for
construction access, except for damage caused by negligence on the Contractor’s part or by overloading of the Contractor’s vehicles. Where the
condition of the existing routes is so poor that it results in inefficient haul of the material or in unavoidable deterioration of the roads, the Contractor
shall request the authority to implement suitable and effective maintenance actions. The Contractor shall refer any maintenance proposals to be
conducted by the Contractor, to the Employer for a decision when the responsible road authority cannot or will not carry out the requested
maintenance.
The Contractor shall keep records comprising counts and categories, of construction vehicles using the public roads and streets.
b) Temporary new roads on acquired land and over private property
The Employer or its agents may acquire land, or register a servitude, or conclude arrangements with the landowner or legal occupant of the land for
the construction of temporary haul and access roads over a property.
Where the Employer or its agents have not made any arrangements for the new roads, the Contractor shall then engage with the landowner or legal
occupant to construct and maintain temporary unproclaimed haul and access roads over the private property. Existing tracks shall be used as far as
possible for haul roads. The Employer shall approve any costs relating to the Contractor’s arrangements prior to concluding an agreement with the
landowner or legal occupant.
The requirements for haul roads not on existing public roads are given in Clause A1.2.3.2 of Chapter 1.
c) Construction requirements for new temporary unsealed roads
In the absence of any specified conditions in the borrow pit or quarry approvals and in the Contract Documentation, the following requirements
shall be complied with for the construction, use and maintenance of new temporary haul and access roads:
• The route shall be selected so that no trees, or a minimum number of trees, are felled and existing fence lines shall be followed as
far as possible;
• Crossing of major water courses and steep gradients shall be avoided as far as is practicable;
• Adequate drainage and erosion protection in the form of side drains, mitre drains, cut-off banks, dykes and temporary culverts shall
be provided where necessary;
• The erection of gates in fence lines and the open or closed status of gates in new and existing positions shall be clarified with the
landowner, legal occupant or tenant and the agreed status shall be maintained throughout the operational period;
• The temporary roads shall be cleared and grubbed as specified in Section A1.6 of Chapter 1. Clearing and grubbing shall be carried
out to 1,0 m wider than the roadbed width of the temporary road;
• Topsoil shall be removed separately and stockpiled for later use in the rehabilitation of the temporary roads, borrow pits or quarries
as specified in Section A1.6 of Chapter 1;
• The necessary agreed roadbed treatment, earthworks, pavement layers and wearing course shall be constructed to accommodate
the type and number of construction equipment passes;
• Temporary roads shall be maintained by blading, backfilling of potholes or re-surfacing as applicable and instructed;
• Whenever dust becomes a nuisance to the public or adjacent properties, the Contractor shall when so ordered by the Engineer,
apply sufficient water or take other measures to lay the dust; and
• Reasonable speeds shall be observed on temporary roads to avoid accidents, excessive noise, dust and injury to livestock or animals.
d) Reinstatement of the temporary unsealed roads
Before completing the shaping, finishing and rehabilitation of the borrow pits and quarries, the Contractor shall consult the requirements of the borrow
pit or quarry approvals, and any applicable Local Authority Regulations and By-laws, to confirm if the materials used to construct the temporary haul
and access roads must be removed and reinstated. If so these materials may be used elsewhere on the project if required, or loaded and hauled
back to the borrow pits and quarries.

The temporary roads can only be left in place where acceptance in writing that it can remain is provided by the landowner or legal occupant over
which property a temporary road has been constructed.
In the absence of any specific conditions in the borrow pit or quarry approvals and in the Contract Documentation, the following minimum requirements
shall be complied with for the reinstatement of the temporary roads:
• The gravel wearing course, cut-off banks, dykes and temporary culverts shall be removed,
• The temporary road shall be shaped to the same level and cross fall to blend in with the surrounding ground, either by removing
excess material or by backfilling hollows and any temporary side drains. Backfilled material shall be compacted with one pass of a
smooth drum roller,
• The road surface areas shall be scarified to promote growth of natural vegetation, or shall be ripped, topsoiled and vegetated when
required in the statuary approvals,
• Where necessary suitable drains and/or banks shall be constructed to prevent erosion, and
• The landowner or legal occupant’s consent of the reinstated road shall be obtained in writing.
A4.1.7.2 Borrow pit and quarry operations

a) General control at the borrow pits and quarries
The Contractor shall be responsible for controlling operations at every borrow pit and quarry to ensure compliance with all the requirements of the
statutory authorisation, approvals and the Contract Documentation. Sufficient tests shall be conducted on the excavated material to ensure that
the quality of the material complies with the specified requirements for the particular layer for which it will be used. The test results shall be
delivered to the Engineer for review.
Prior to commencement of the works, the Contractor shall stake the boundary of the borrow pit or quarry area, and erect the boundary beacons. A
stock proof or pedestrian fence as required or specified shall be erected along the boundaries. No borrow pit or quarry shall be extended nor shall
any sourcing and stockpile operations be conducted beyond the boundaries. Only approved personnel shall be allowed access to the borrow pit and
quarry areas.
The Contractor shall keep a digital photographic record of every borrow pit and quarry at regular intervals, from before any investigation or
exploratory works are done until the closure. Photos shall be labelled with the date, borrow pit or quarry number or name, and description of the
activity. The records shall be submitted monthly to the Engineer.
Quantities shall be calculated from topographical surveys carried out by the Contractor at the following stages:
• After clearing and grubbing and before any material is excavated.
• After removal of the topsoil and of the overburden.
• At completion of the excavation and of the finishing, to compile the closure plan of the borrow pit or quarry.
The Contractor shall carry out the following duties for the control at the borrow pits and quarries:
• Implement all the requirements and conditions of the borrow pit and quarry approvals,
• Manage any subcontractors such as for the blasting and crushing operations,
• Ensure compliance with the relevant Health and Safety Act and Regulations and that the excavation and workings in the borrow pit
or quarry are safe,
• Mitigate environmental impacts,
• Ensure that careful and continuous selection of materials is done during the excavation as specified in Clauses A4.1.7.2g) and
A4.1.7.2h),
• Report at least weekly on the quantity and quality of the materials excavated, produced and stockpiled, and
• Give a notice or an early warning of any anticipated future problems.
When specified in the Contract Documentation, the Contractor shall have a full time or part time materials manager to conduct and manage the
duties for the control at the borrow pits and quarries. The requirements for the materials manager, whether the person shall be an engineering
geologist, engineer, a senior materials technician or a senior general foreman, and the required qualifications and experience of the materials
manager, shall then also be specified.
b) Classes of excavation
The excavation of borrow material shall be classified as follows:
(i) Soft excavation
Soft excavation class is excavation of material that can be efficiently removed by the reference construction equipment specified in
the Contract Documentation, without prior breaking down.
Very dense granular or sand material and stiff to very stiff cohesive clay material, which can still be removed by the reference
construction equipment without prior breaking up as specified for hard material but that do not comply with the definition of efficient
removal of the equipment, shall also be classed as soft excavation.
In the absence of any construction equipment specified to reference the efficient removal of the material, a hydraulic crawler excavator
in good mechanical order with nett horsepower (flywheel power) generally between 180 kW and 225 kW, also known as a 30 ton
excavator, and equipped with a heavy duty bucket shall be the reference construction equipment. A minimum continuous production
rate of 160 m3/h of the excavated material will be taken as the benchmark for the excavator’s capacity and efficiency.
(ii) Boulder excavation class A
Where material contains in excess of 40 % by volume of boulders, core stones, floaters and lumps of hard material larger than
200 mm but volume less than 20 m3 in size, in a matrix of soft material, then the full volume excavated shall be classed as boulder
excavation class A.

Excavation in dolomite formations other than solid dolomite shall also be classed as boulder excavation class A if the formations
contain in excess of 40 % by volume of lumps of hard dolomite larger than 200 mm but volume less than 20 m3 in size, in a matrix of
softer material or smaller lumps of hard dolomite.
Excavation of fissured or fractured rock shall not be classed as boulder excavation but as soft or hard excavation according to the
nature of the material.
(iii) Boulder excavation class B
Where material contains 40 % or less by volume of boulders, core stones, floaters and lumps of hard material larger than
200 mm but volume less than 20 m3 in a matrix of soft material, then the volume of the individual boulders, core stones, floaters and
lumps of hard material shall be classed as boulder excavation class B.
The volume of the rest of the material shall be classed as soft excavation.
(iv) Hard excavation
Hard excavation is excavation of material, excluding boulder excavation that is classed separately, which cannot be removed efficiently
by the reference construction equipment specified in the Contract Documentation, and that will require other means of breaking down
before removal by one of or a combination of the following:
• Drilling and blasting.
• Ripping with a bulldozer.
• An excavator fitted with a hydraulic percussion hammer or fitted with a ripper.
• Hand operated pneumatic or electro-mechanical equipment such as jackhammers or pavement breakers.
• Drilling and injecting non-explosive, expansive, silent rock-breaking cracking products.
Excavation of individual large boulders, core stones and lumps of hard material in excess of 20 m3 shall also be classed as hard excavation.
The Contractor shall be at liberty to use any method and construction equipment for excavating any class of material, but the chosen method or
construction equipment to excavate the material shall not dictate the classification of the material.
Before any excavation commences the Engineer and the Contractor shall agree on the applicable classes of excavation, based on a visual
inspection, any geotechnical information issued with the Contract Documentation and the supplementary explorations as in Clause A4.1.7.2c).
Agreement shall also be reached on the method of measurement to be used for boulder excavation or blasted rock prior to the commencement
of the excavation.
In the event of a disagreement between the Engineer and the Contractor, the Contractor shall if instructed, make available such reference construction
equipment as specified at no cost to the Employer, in order to determine whether or not the material can be efficiently removed. The decision of the
Engineer as to the classification shall thereafter be final and binding, subject to the relevant provisions of the Contract Documentation.
The Contractor shall immediately inform the Engineer if and when the nature of the material being excavated changes to such an extent that a
new classification for further excavation is warranted. Failure to inform the Engineer of any possible change in the class of excavation before the
material is excavated, shall entitle the Engineer to classify and measure such excavation as deemed appropriate.
c) Supplementary exploration
When agreed to by the Engineer and the Contractor, the Contractor in the presence of the Engineer, shall conduct further investigations to obtain
information for the M&U plan of a borrow pit and of a quarry. In doing so the Contractor shall:
• Recommend and request additional trial pits and/or drilling to substantiate the material properties tested during the exploration at the
design stage,
• Determine the extent of the clearing and grubbing,
• Determine the thickness of the topsoil,
• Determine the thickness of the overburden, and quality for use in appurtenant works,
• Determine the thickness, quality and quantity of compliant material for earthworks and pavement layers,
• Assess the class(es) of excavation for proposing to the Engineer,
• Determine the sufficiency of the available material compared to the mass haul or information in the Contract Documentation,
• Recommend proposals to supplement any material shortage, and
• Determine any other input required for the Contractor’s M&U plan.
d) Clearing and grubbing
The borrow pit or quarry from where material is to be sourced shall be cleared and grubbed as specified in Section A1.6 of Chapter 1.
Borrow pits and quarries shall be cleared and grubbed 2,0 m wider than the excavated area or to 2,0 m beyond the outer edge of temporary drainage
banks and dykes, as applicable. Material obtained from clearing and grubbing of an area, provided it is not hazardous material, shall be removed to
temporary stockpile within the borrow pit or quarry area. Upon closure, it can be placed within the borrow pit or quarry and covered up. The burning
of material on the site of the works shall not be permitted.
Where the total thickness of the topsoil and the overburden is more than 1,0 m, all trees and tree stumps including mattered roots shall be removed
to a depth of at least 1,0 m below the cleared surface. Where the total thickness is less than 1,0 m a separate grubbing operation is not required and
the tree stumps can be removed together with the overburden, unless otherwise instructed by the Engineer.
Individual boulders, core stones, floaters or lumps of hard material which are exposed or lying on the surface and that cannot be removed by the
construction equipment used in the clearing and grubbing operation, shall be separated (pushed aside) and left in the borrow pit, or shall be broken
down and then removed to spoil or to the road if suitable after breaking down or to a crushing plant for crushing. Breaking down or crushing of the
material shall be approved or instructed by the Engineer.

e) Removal and conservation of the topsoil
After the clearing and grubbing of an area, the topsoil shall be excavated and stockpiled as specified in Section A1.6 of Chapter 1, for later rehabilitation
of the borrow pit or quarry. It shall be stockpiled in a designated area as indicated on the borrow pit or quarry plan.
f) Removal of the overburden
No removal of overburden or any further borrow pit/quarry operations shall commence until agreement has been reached with the Engineer in
regard to the thickness, the extent, use and quantity of the overburden. Overburden less than 200 mm thick shall be removed with the topsoil and
not separately.
Overburden shall be moved to beyond the outer limits of the borrow pit or quarry excavation. This operation shall not be regarded as temporary
stockpiling. The Engineer’s approval must be obtained for removing and stockpiling of overburden that cannot be moved to beyond the limits of
the borrow pit or quarry excavation, or for overburden that is to be used in the works. Overburden shall be kept in a weed-free condition during
the construction.
The remaining overburden material shall be placed in the borrow pit or quarry at completion of the borrow operations and levelled.
g) Selection and excavation of material in borrow pits
Once the material compliant for the works is exposed in a borrow pit, the Contractor shall:
• Plan the utilisation in such a manner that the pioneer and fill material can be selected, excavated and loaded directly for use on the
road. Only after approval, where the fill layers cannot be constructed immediately or for reasons beyond the Contractor's control,
shall the material be temporarily stockpiled. The Contractor shall cease excavation of the fill material until it can be processed on
the road, at no cost to the Employer.
• For all the pavement layer materials the Contractor shall always select, excavate, remove and place the material into compliant
separate stockpiles to provide a uniform material, prior to removal of the material to the road. Where it is not feasible to stockpile
the material within the borrow pit or borrow pit area the Engineer shall designate other temporary stockpile areas elsewhere outside
the borrow pit area. Measurement and payment shall be made for this stockpile activity.
Borrow material shall be excavated within the depths and area shown on the borrow pit and M&U plans, in a manner that shall not prejudice the
use of the material for the intended purpose.
The material in the borrow pits shall be broken down during the excavation to the following maximum particle sizes, depending on the use
envisaged for the material, before it is loaded:
• Pioneer material 500 mm.
• Rockfill 500 mm.
• Coarse fill 500 mm, but not exceeding the thickness of the fill layer for efficient compaction by the construction equipment.
• Normal fill 300 mm.
• Pavement layers 300 mm.
• Material to be crushed, to a maximum size that will suit the take of the crusher.
In order that the material can be broken down to the above-mentioned sizes, the Contractor shall adjust and control the blasting, ripping, excavating
and other operations so that the desired result can be achieved. Drilling and blasting patterns shall be such as to break down the material to the
specified sizes, and where this is impractical, secondary blasting or other methods shall be used for breaking down oversize materials.
Where the working methods of the Contractor are such that large quantities of oversize material are produced, the Contractor will be instructed to
change the working methods, or type of crushing and screening plant, or construction equipment in order to produce less oversize material.
Excessive breaking down of the finer fraction of the material and thereby altering the properties of the material shall be avoided. Any material so
altered shall be replaced by the Contractor at any cost to the Employer.
Where any borrow pit contains different types of materials in separate layers which require to be mixed (blended) to produce a compliant pavement
layer product, then:
• The materials shall be excavated over the full depth of the working face in one operation without the different types of materials being
separated, or
• The materials shall be pushed into heaps by a dozer and then loaded in one operation over the full height of the heap, or
• The materials from the separate layers shall be excavated individually, removed to stockpile, placed and spread in alternate layers.
Loading into the trucks for transport to the road shall then be done with a hydraulic excavator stationed on top of the stockpile and
filling its bucket through the full height of the stockpile.
Such mixing (blending) of material shall not be classified as mechanical modification but considered as normal borrow pit operations.
The Contractor shall take all reasonable precautionary measures to avoid contamination of the compliant borrow material with clayey or other
non-compliant material from the floor of the excavation, or from the overburden not previously removed, or from any other non-compliant layers
in the excavation face. The Contractor shall monitor the quality of material with increasing excavation depth as the quality of some materials may
vary with depth. Where the Contractor has contaminated or wasted compliant material, replacement material shall be supplied by the Contractor
at no cost to the Employer.
When there is any doubt concerning the quality of the borrow material being excavated at any time, the Contractor shall give notice before such
material is removed to stockpile or hauled to the road or to the crusher. After further testing or inspection by the Engineer as required, the
Contractor will be instructed regarding the use of the material or may be ordered that the borrow pit be finished off and abandoned.
During borrow operations, and especially when excavating material near the floor and outer boundaries of the borrow areas, the Contractor shall
plan his operations to reduce, in so far as is possible, the amount of earth moving work that will be necessary for shaping and finishing the borrow
pit. Indiscriminate excavation without due regard being given to the desired final shape shall not be permitted.
When blasting is to be carried out in medium to hard rock, the surface of the exposed rock shall be cleaned of all loose and foreign material that
can affect the quality of the blasted material. The rock shall be blasted to sizes without further breaking down that comply with the specified
maximum particle sizes for blasted rock in rockfill and for pioneer material, and for material to be crushed to suit the take of the crushing plant.

Rippable material which tends to break into large blocks shall be cross ripped.
Surface water shall be continuously prevented from flowing into or standing in the excavations. The Contractor shall construct temporary banks
and dykes for diverting surface water and plan the operations in such a way that the borrow pit shall be self-draining. Where this is not feasible
during the excavation, it shall be dewatered by pumping. The Contractor shall ensure that borrow material is sufficiently dry when required for use.
The Contractor shall carry out the following duties during the selection and excavation of the materials:
• Ensure that the borrow pit is managed and utilised in terms of the M&U plan prepared in accordance with the requirements of Clause
A4.1.3.3,
• Ensure that the excavation, side slopes, finishing and the like are done in accordance with the borrow pit plans approved by the
relevant authority,
• Report immediately any changes in the excavation class and material quality,
• Monitor the quality of the excavated material by process control laboratory testing,
• Ensure proper selection of the material,
• Manage the removal of the material to the road or to the stockpile or to crushing,
• Record the number of vehicles and volumes of material when the volume of material is measured as a percentage of the loose
volume in haul vehicles, and
• Control the rehabilitation and closure of the borrow pit.
When specified in the Contract Documentation, the Contractor shall have an excavation controller to carry out the above-mentioned duties for the
selection and excavation of the materials. The requirements for the excavation controller, whether the person shall be a materials technician or
a general foreman, the controller’s required qualifications and experience, and whether the controller shall be full time or only part time at the
excavation, shall then also be specified.
h) Selection and excavation of materials in quarries
After removal of the topsoil and overburden, as applicable, the bedrock shall be cleaned of all loose and foreign material that have remained, and
that can affect the quality of the crushed rock.
Blasting shall be done in depths and levels agreed to in the M&U plan. The rock shall be blasted to sizes without further breaking down that
comply with the specified maximum particle sizes for blasted rock in rock fill and for pioneer layer material, and for material to be crushed to suit
the take of the crushing plant.
The floor of a blasting shall be cleaned of all loose material, prior to the next blast. Any loose material from the excavation face shall also be
removed before proceeding. Benches shall be provided in the faces of the excavation for stability and safety, as specified in the Contract
Documentation or as instructed by the Engineer upon advice from an experienced geologist or engineering geologist.
Measures to ensure that all seams of deleterious material within the rock body are avoided or separated out from the blasted rock before it is
crushed shall be included in the M&U plan.
The blasted material shall be loaded and hauled to the crushing and screening plant. Non-compliant material shall not be taken to the plant but
shall be taken to temporary stockpile or left in the quarry out of the way.
The Contractor shall monitor the quality of the rock material. When there is any doubt concerning the quality of the material at any time, the
Contractor shall give notice before such material is removed. After further testing or inspection by the Engineer as required, the Contractor shall
be instructed regarding the use and processing of the material, and/or workings in the quarry.
Surface water shall be prevented from flowing into or standing in the excavation. The Contractor shall construct temporary banks and dykes for
diverting surface water and plan the operations in such a way that the quarry shall be self-draining.
The Contractor shall carry out the following duties during the selection and excavation of the materials:
• Ensure that the quarry is managed and utilised in terms of the M&U plan prepared in accordance with the requirements of Clause
A4.1.3.3,
• Ensure that the excavation, side slopes, finishing and the like are done in accordance with the quarry plans approved by the relevant
authority,
• Monitor the quality of the excavated material by process control laboratory testing and report immediately any changes,
• Manage the removal of the material to the road or to the stockpile or to crushing,
• Record the trucks and volumes of material when the volume of material is measured as a percentage of the loose volume in haul
trucks, and
• Control the rehabilitation and closure of the quarry.
When specified in the Contract Documentation, a materials manager shall carry out the above-mentioned duties for the selection and excavation
of the materials. The requirements for the materials manager, whether the person must be an engineering geologist, engineer or materials
technician, the required qualifications and experience of the manager and whether the manager must full time or part time at the quarry or quarries,
shall then also be specified.
i) Use and treatment of oversize material in borrow pits
Excavated material from borrow pits that contains oversize material, that is material exceeding the specified maximum particle sizes in Clause
A4.1.7.2g), shall be handled as follows:
• Where the material contains less than 5 % by volume of the oversize material, the material can be hauled to the road or placed in
the stockpile. The oversize material shall then be broken down by using appropriate compaction rollers or bladed out of the layer or
removed by hand on the road, and then later returned to the borrow pit as spoil material or to a crusher, if available, for crushing.

• Where the material contains more than 5 % by volume of oversize material but the excess volume is mainly due to a few large
oversize rock particles, cobbles or boulders, the larger oversize materials shall not be loaded during the excavation but shall be left
in the borrow pit, unless instructed otherwise. Where the remaining material then has less than 5% by volume of oversize material,
it can be hauled to the road or to the stockpile.
• Where the material contains more than 5 % by volume of oversize material, even after removing the large oversize particles, the
Engineer shall instruct before the material is loaded at the excavation whether all the material, including the non-oversize material,
shall be crushed and/or screened, or further broken down in the borrow pit or on the road, or whether further excavation of the
material shall be avoided. Removing large quantities of oversize material from the road shall be avoided.
During loading, any hard oversize material that will not break down during processing on the road shall be excluded.
Oversize material larger than 500 mm left in the borrow pit shall be broken down to a maximum size of 500 mm before it is covered over with
softer material when the borrow pit or quarry is finished and rehabilitated.
j) Explosives and blasting
Explosives shall be used in accordance with the requirements and specifications given in Clause A1.2.7.5 of Chapter 1 and Section A12.10 of
Chapter 12.
All blasting operations shall be carried out in accordance with the requirements and specifications given in Section A12.10 of Chapter 12.
k) Producing the materials by crushing and screening
(i) Borrow pit materials
Oversize material that must be reduced in size to comply with the requirements of the specified maximum particle sizes of the material
types in the pavement layers, and any other material instructed or approved by the Engineer, shall be screened, crushed or crushed
and screened.
Screening only of the material shall be done by screening out oversize material by a grizzly type screen, or by the use of mesh
screens, or by screening the material into various fractions through a series of screens and thereafter if still necessary, blending some
of the fractions to obtain a compliant material.
Crushing shall be accomplished by either a single-stage or a two-stage crushing plant. The Engineer shall instruct breaking down of
the material before crushing to suit the take of the crusher, if required.
A single-stage crushing plant comprises only a primary crushing unit in which only a reduction to a maximum size occurs. The single-
stage crushing plant shall be capable of crushing oversize material to the maximum size specified for the type of material and layer
thickness.
A two-stage crushing plant, while not always necessary to achieve the required reduction ratio, comprises a secondary crushing plant
in addition to the primary crushing unit. The two-stage crushing plant shall be capable of crushing the material to ensure that the
grading of the product falls within the specified envelope, producing sufficient fines as well as yielding the specified shape
characteristics.
For single-stage and two-stage crushing plants, additional selective screening may be required.
Medium to hard rock in borrow pits for types G4A and/or G5A material, shall be produced by multi-stage crushing, similar to specified
for quarry materials.
(ii) Quarry materials
Material sourced from quarries shall always require crushing and screening.
A multiple-stage crushing plant consisting of two or more crushers, is required to control the grading and shape of the higher quality
material types, as well as surfacing and concrete aggregates. Multiple-stage crushing shall always require screening of the material.
After crushing and screening, the different material types required for use in the pavement layers shall be stockpiled as specified in
Clause A4.1.7.3.
l) Use of the borrow material
The results of laboratory tests, trial pits and borehole drilling of materials carried out during the design stage are included in the Contract
Documentation. The results and other information give a preliminary indication as to the purpose for which and where the material shall be used.
The Engineer shall give final instructions during construction regarding the use of the borrow material.
Coarse rock encountered shall be utilised for the construction of the lower layers of fills high enough to accommodate thick layers, or, where so
required, shall be conserved and used as directed for constructing the sides of embankments or for serving as protection against embankment or
channel erosion.
The Engineer may order that particular materials in the borrow pits and quarries be selected for a specific purpose. Where selection is ordered,
the method of excavation and the programme of work shall be so arranged as to avoid double handling. When ordered by the Engineer, the better
class fill material shall be selected for use in the top layer of the fills and in the lower layers of high fills.
Any surplus or non-compliant material resulting from the excavation shall be disposed of as directed by the Engineer.
The Engineer shall have full control over the use of all borrow pit and quarry materials. The Engineer shall have the right to decide which borrow
pit or quarry the Contractor shall operate from at any particular stage of the work, and to deviate from any previous programme of material source
at no additional cost to the Employer.
The Contractor shall plan the operations and particularly the excavation-to-fill operations in such a manner that all borrow material be used to the
best advantage of the Employer. This means that no material shall be unnecessarily spoiled, borrowed, stockpiled or hauled. The Contractor shall
neither borrow nor spoil any material without the Engineer’s approval and without proving to the Engineer that this is necessary and that it is the
most economical method of constructing the works.
m) Closing of the borrow pits and quarries
The operations and requirements for shaping, finishing, rehabilitation and closure of the borrow pits and quarries after the removal of the road
construction material is completed, are contained in the borrow pit and quarry plans approved by the control authority and shall be complied with.

In the absence of any specified conditions in the borrow pit or quarry approvals, or elsewhere in the Contract Documentation, the following
minimum requirements shall be complied with:
• All gravel and soil material in the borrow pit and quarry areas outside the borrow pit or quarry, whether spoil from the road construction
operations, excess stockpiled material, any material from the stockpile fill platform, oversize material left in the borrow pit, material
from temporary banks and material resulting from clearing and grubbing operations shall be placed in the floor of the borrow pit or
quarry. The material shall be spread evenly and the floor shall be shaped to prevent standing water,
• Material placed in the floor of the borrow pit or quarry incapable of supporting natural vegetation shall be covered with soft material
or topsoil,
• Remaining portions of in situ soft material in the floor shall be scarified along the contours so that undue erosion is avoided. Hard
material in the floor shall be left intact,
• The floor of the borrow pit or quarry shall generally not be vegetated, unless required in the statutory authorisation or instructed by
the Engineer,
• All infrastructure and foundations for buildings and the crushing plants shall be demolished and removed and the surface covered,
• All foreign materials shall be removed,
• Domestic or other waste and rubbish shall not be disposed of in the borrow pit or quarry but shall be removed from the site,
• Hazardous material as specified in Clause A4.5.5.5 shall not be spoiled or buried in the borrow pit or quarry,
• Soil contaminated with oil or grease or fuel or other hydrocarbons shall not be disposed of in the borrow pit or quarry excavation but
shall be removed from the site,
• Existing banks and dykes shall be reconstructed if required, or new banks and dykes shall be constructed to divert surface water
from or around the excavation. Stormwater shall also not be concentrated on the property of an adjoining landowner or legal occupant,
• The excavation shall be self-draining or where this is not possible the control authority’s approval shall be obtained,
• Unless otherwise specified in the Contract Documentation and/or environmental and mining approval documents, large boulders or
remaining in situ hard material can be left to protrude from the slopes or faces of the excavation,
• The slopes (sides or batters) within soft excavation shall be shaped not steeper than 1 vertical to 3 horisontal,
• All loose and unstable material shall be removed from the faces of excavation in boulder or hard material,
• The finished surfaces in soft material that will be topsoiled shall not have any loose stones larger than 100 mm,
• The soft material embankments shall receive a 75 mm to 150 mm thick topsoil layer, and shall be vegetated when measured in the
Pricing Schedule, and
• The entire borrow pit or quarry area shall be fenced along with appropriate access control signage and with a locked gate for access
if required, except if the area is not accessible by the public, there are no slopes steeper than 1 vertical to 3 horizontal in the hard
material areas and the Engineer, the landowner or legal occupant and the relevant authority agree in writing that it is safe to leave
the borrow pit or quarry area unfenced.
A4.1.7.3 Stockpiles
a) Preparation of the stockpile site
Stockpile sites shall be prepared in positions as indicated on the borrow pit or quarry plans, or at positions agreed to and indicated on the M&U
plans.
Before any stockpiling may be done the area shall be cleared and grubbed as specified in Section A1.6 of Chapter 1. The area to be cleared and
grubbed shall be 2,0 m wider than the footprint of the stockpile or to 2,0 m beyond the outer edge of temporary banks and dykes, as applicable.
Topsoil and overburden material can remain in place, except when it has insufficient bearing strength for the height of the stockpiled material or
where a platform of fill material must be constructed. The topsoil shall then be removed and stockpiled in an area that will not be affected by
construction activities nor impede the natural flow of water. The stockpiled topsoil and its immediate surrounds shall be kept free of all undesirable
vegetation.
Trees and tree stumps shall be removed to 75 mm below the cleared surface.
Stockpile areas shall be constructed with a minimum slope of 2 % to ensure proper drainage. The surface (floor) shall be scarified to a depth of
150 mm, watered, and compacted to a minimum density of 90 % of MDD. Further instructions will be given for the treatment of soft in situ material
with low bearing strength, in accordance with the roadbed treatments specified in Section A5.1 of Chapter 5.
On steep sloping landforms, a platform shall be constructed so that the cross fall does not exceed 5 %. The platform shall be constructed of fill material
in layers compacted to a minimum density of 90 % of MDD. The compacted surface for stockpiling shall be firm and clean of loose material.
Stockpile areas shall be large enough to allow the different types of material to be stockpiled without overlapping or exceeding the limits of the borrow
pit or quarry area or indicated stockpile area.
The Contractor shall ensure that stockpiled material is not washed away during rain. Temporary banks must be constructed on the high side of
stockpiles to divert surface water. Care must also be taken to prevent water from damming up against the stockpiles. On the lower side of the stockpile
material, temporary banks with stormwater outlets shall be constructed to contain any stockpile material that is washed down during rain.
The Contractor shall only commence the stockpiling activities after the areas have been prepared and approved by the Engineer.
b) Stockpiling of the material
The material shall be off-loaded and spread uniformly in layers in the stockpile. Segregation of the material during the handling shall be avoided.
The different material stockpiles shall be sign posted according to the material type and intended use.

Where different types of excavated or commercial materials are placed in the same stockpile for mixing later on the road for the mechanical
modification of pavement layer material, the materials shall be placed in lift heights of less than one metre. The different materials shall be placed
in layers in every lift, in thicknesses of the same proportion as in the final material mix determined by testing.
The height of stockpiles that consists of different layered materials shall not exceed 3,0 m to enable efficient mixing of the materials during loading
to the road. Stockpiles that consist of uniform materials can be built higher depending on the capacity of the loading equipment, unless restrictions
are placed on the height in the environmental or other approvals.
Special attention shall be given to the stockpiling of crushed stone material for a base layer. It shall always be placed in stockpiles after crushing.
The material shall be dumped and levelled in the stockpile so that any segregated material from the processing operation is blended again.
However, extensive working of the crushed stone material in the stockpile shall be prevented to avoid segregation. The side slopes of the stockpile
shall be visually assessed for areas or layers of obvious fine or coarse material that is indicative of segregation.
The lower 100 mm of stockpiled material shall not be loaded for construction to avoid contamination with the floor or platform material of the
stockpile.
The Contractor shall carry out the following duties at every stockpile:
• Ensure that the stockpile site has been prepared correctly and that all banks and dykes are in place before stockpiling commences,
• Ensure that the material is placed at the correct designated stockpile,
• Manage the correct proportional placing of different materials in the specified lift heights if applicable,
• Ensure that the specified stockpile heights are not exceeded,
• Ensure that the stockpile slopes are safe and not prone to excessive segregation at the edge,
• Regularly inspect and maintain the stormwater banks and dykes,
• Ensure that material washed from the stockpile is contained,
• Control the safe movement of construction equipment, vehicles and personnel on the stockpile site,
• Comply with all the conditions of the borrow pit and quarry approvals by the control authority and in the Contract Documentation, and
• Comply with the requirements of the relevant legislation relating to OHS, Mining and Construction.
When specified in the Contract Documentation, the Contractor shall have a stockpile controller at every stockpile site to conduct and manage the
above duties. The requirements for the stockpile controller, whether the person must be an assistant materials technician or a junior foreman and
whether the controller is to be present full time or only part time during the stockpiling, as well as the controller’s required qualifications and
experience, shall then also be specified.
c) Reinstatement of the stockpile site
After the stockpiled material has been removed, the site shall be reinstated as closely as possible to its original condition.
In the absence of any specified conditions in the borrow pit or quarry approvals, or elsewhere in the Contract Documentation the following minimum
requirements shall be complied with:
• All surplus stockpiled material shall be removed and disposed of,
• Material used to construct a fill platform and the temporary banks shall be removed and disposed of, unless the Contractor is
instructed to leave the banks in place to prevent future erosion,
• The stockpile floor shall be graded to the original natural contours,
• The stockpile floor shall be ripped 100 mm deep to break all compacted in situ material, and
• The stockpile site shall be lightly scarified to promote growth of natural vegetation or shall be covered with a 75 mm to
150 mm thick topsoil layer and vegetated when required in the statuary approvals.
A4.1.7.4 Weighbridge facility

Weighing of materials for measurement and payment purposes, if applicable, shall be carried out by a temporary weighbridge facility erected on
the site, or by a permanent offsite weighbridge facility.
The temporary weighbridge facility shall consist of a weighbridge and an equipped office. The weighbridge shall be:
• Of sufficient length and width to accommodate the largest truck that will have to be weighed,
• Erected on shaped and compacted ground with concrete approaches,
• Equipped with loadcells for weighing,
• Able to weigh trucks shorter than the length of the weighbridge and standing anywhere on it,
• Able to weigh the maximum gross weight of the loaded trucks being used, and
• Calibrated after it is commissioned before it is first used and thereafter at least every six months.
The weighbridge office shall be:
• A waterproof structure that can be locked,
• Able to accommodate the weighbridge operator and computer hardware, and
• Equipped with its own generator for power supply,

The computer software shall be able to record, store and keep a complete electronic data base of:
• The various products,
• The registration details of all weighed trucks,
• The gross (product and vehicle), tare (the vehicle) and the nett (product) weights of every truck, and
• The daily and monthly product reports of at least the nett weights.
A weighbridge operator shall be stationed full time in the weighbridge office for the operation of the weighbridge facility when in use.
A permanent weighbridge facility shall be in possession of a SANAS verification certificate not older than 2 years.
A4.1.8 WORKMANSHIP
The Engineer and the Contractor shall determine and agree on the testing protocol and frequency of the applicable process and quality control
tests required for each type of the sourced borrow materials to ensure that the quality of materials produced meets the specified requirements for
the particular road pavement layer for which it will be used. These required laboratory tests and testing frequencies shall be stated in the borrow
pit and quarry M&U plans.
Measurement, testing, and evaluation of all individual components and constructed products shall be in accordance with the methods prescribed
in this Section or in Chapter 20 as relevant.

B4.1 BORROW MATERIALS
CONTENTS
B4.1.1 SCOPE
B4.1.2 DEFINITIONS
B4.1.3 GENERAL
B4.1.5 MATERIALS

B4.1.8 WORKMANSHIP
B4.1.1 SCOPE
This Section covers the work involved in sourcing materials from borrow pits and quarries that are developed and operated to supply materials for
a specific road construction project or projects.
A relatively small proportion of activities as defined in Part A under the various sections are considered suitable for labour enhancement.
Part B only provides additional specifications, not contained in Part A.
B4.1.2 DEFINITIONS
Definitions as provided in Chapter 1 and Clause A4.1.2 shall also apply.
B4.1.3 GENERAL

B4.1.5 MATERIALS

Where reference is made in Part A to appropriate equipment, the use of light equipment shall be evaluated during trial sections.

For Borrow Materials, the finishing of the borrow pit and quarry areas and the stockpile sites are suitable components for labour enhancement.
B4.1.8 WORKMANSHIP

C4.1 BORROW MATERIALS
(i) Preamble
Where pay item descriptions include any wording in brackets, it is an indication that contract specific information is to be inserted in the Pricing
The following required activities will not be measured or paid for separately and the Contractor shall include the cost thereof in items describing
the activity or other items as deemed appropriate:
1. Loading and hauling to any of the following borrow pit and quarry operations required to source and produce the material that are carried out
within the same borrow pit and quarry areas:
- Removing, and stockpiling if required, of the topsoil and of the overburden.
- Moving the excavated material between the point of excavation and the stockpile sites or crushing and screening areas, and between
the crushing and screening areas and the stockpile sites as applicable.
- During rehabilitation of the stockpile sites removal of the surplus material, the fill platform, temporary banks and material generated in
the finishing.
2. Separating oversize material to be left in the borrow pit.
3. Moving of the construction equipment from one borrow material location to another.
For activities in Table C4.1-1 items specified in other Chapters or Sections of the specification, where they relate to work under this Section, will
be listed in the Pricing Schedule.
Fencing and gates around the borrow pit and quarry areas A4.1.7.2a)
applicable items
Clearing, grubbing, removal of large trees, and removal of
A4.1.7.2d) and A4.1.7.3a) C1.6.1 to C1.6.4 of Chapter 1
buildings and structures
Conservation (excavating and stockpiling) of topsoil A4.1.7.2e) C1.6.9 of Chapter 1
(including overburden less than 200 mm thick)
Banks and dykes A4.1.7.2h) and A4.1.7.3a) C3.1.6 of Chapter 3
Blasting of hard material A4.1.7.2j) C12.10.1 of Chapter 12
Hauling material (when applicable) A4.1.7.2k) and A4.1.7.3b) C1.7.2 of Chapter 1

Placing of topsoil, and vegetation A4.1.7.2m)
applicable items

C4.1.1 Compiling and implementing M&U plans
C4.1.1.1 For borrow pits (list all borrow pits separately) number (No)
C4.1.1.2 For quarries (list all quarries separately) number (No)
The unit of measurement shall be the number of compiled M&U plans for borrow pits and quarries.
The tendered rates shall include full compensation for gathering all information and compiling the plans, for topographical surveys and for ensuring
the implementation of the plans during the operation of the borrow pit or quarry.

C4.1.2 Additional material investigations during the supplementary exploration
C4.1.2.1 Cost of additional trial pits and/or drilling and laboratory testing provisional sum
C4.1.3 Construction and maintenance of temporary haul and access roads
C4.1.3.1 Temporary unsealed roads kilometre (km)
C4.1.3.2 Cost to repair existing public roads or streets provisional sum
C4.1.3.3 Handling cost and profit in respect of item C4.1.3.2 percentage (%)
The unit of measurement for item C4.1.3.1 shall be the kilometre of temporary unsealed haul and access roads constructed in the contract.
The tendered rate for item C4.1.3.1 shall include full compensation for all loading and hauling material, constructing the completed road,
maintaining it including watering for dust control, removing the road, banks and dykes at the end of its use and for revegetation.
Any haul costs shall be included in the tendered rate of item C4.1.3.1.
Drainage culverts and fencing shall be measured separately.
Item Description
Unit
C4.1.4 Removing of the overburden
C4.1.4.1 In borrow pits cubic metre (m3)
C4.1.4.2 In quarries:
(a) Soft material cubic metre (m3)
(b) Hard material (by blasting) cubic metre (m3)
The unit of measurement shall be the cubic metre of overburden removed.

The quantity shall be measured in place at the borrow pit or quarry before stripping. It shall be based on the thickness of overburden as measured
in trial pits, or from topographical surveys carried out after the removal of the topsoil and surveys done after the removal of the overburden.
Overburden less than 200 mm thick when removed with the topsoil shall be included in the topsoil measurement.
For removing overburden in borrow pits no distinction shall be made between the classes of excavation of the overburden material.
For removing overburden in quarries distinction shall only be made between removing soft and hard material.
The tendered rates shall include full compensation for excavating the overburden, for moving the material to the outer limits of the borrow pit or
quarry or for loading the material for stockpiling as applicable, for replacing the overburden in the borrow pit or quarry after completion of the
excavation including loading and hauling from the stockpile when applicable, and for levelling the material.
The tendered rate for item C4.1.4.2b) shall exclude the cost of blasting, which shall be measured and paid for under item C12.10.1 of Chapter 12.
Approved stockpiling of the overburden shall be measured and paid for under item C4.1.12.
C4.1.5 Excavating of materials in the borrow pits and quarries, material obtained from
C4.1.5.1 Soft excavation cubic metre (m3)
C4.1.5.2 Boulder excavation class A cubic metre (m3)
C4.1.5.3 Boulder excavation class B cubic metre (m3)
C4.1.5.4 Hard excavation (other than by blasting) cubic metre (m3)
C4.1.5.5 Hard excavation (by blasting) cubic metre (m3)
The unit of measurement in each class of excavation shall be the cubic metre of material excavated.
The quantities shall be measured in place in the compacted earthworks or pavement layers. The quantities shall not include excess material,
overfill material or additional material placed for bulking (settlement during compaction).
The quantities for earthworks shall be measured from the difference between surveyed cross sections at 20 m maximum intervals taken before
and after the construction of the earthworks.
The quantities for pavement layers shall be calculated from the authorised dimensions of the layers. Where the pavement layer materials are
placed in stockpile for some time before used on the road, the Engineer and the Contractor shall agree on the interim method of measuring the
quantities for this item.

For boulder material the Engineer may approve that the quantities be measured in haul vehicles as an alternative when the boulder material
cannot be identified accurately prior to excavating, by taking the volume of the material as equal to 50 % of the loose volume of the material in the
haul vehicles.
The tendered rates shall include full compensation for breaking down the materials in the various classes to the specified maximum particle sizes,
for excavating, and loading the material.
The tendered rate for item C4.1.5.5 shall exclude the cost of blasting, which shall be measured and paid for under item C12.10.1 of Chapter 12.
Item Description
Unit
C4.1.6 Providing crushing, screening and related plants
C4.1.6.1 Single-stage crushing plant number (No)
C4.1.6.2 Two-stage crushing plant number (No)
C4.1.6.3 Multiple-stage crushing and screening plant number (No)
C4.1.6.4 Screening plant number (No)
C4.1.6.5 Etc, for other plants (as stated by the Engineer and/or the Contractor) number (No)
The unit of measurement shall be the number of complete plants supplied and erected on the project.
The tendered rates shall include full compensation for providing the plant, transporting the plant to the project, erecting, commissioning and finally
dismantling it, and removing it when it is no longer required for the project.
Payment of this item shall be made in two instalments as follows:
• The first instalment, 85 % of the tendered rate, shall be paid after erection and commissioning of the plant.
• The final instalment, 15 % of the tendered rate, shall be paid after removal of the plant from the contract.
C4.1.7 Producing the material by
C4.1.7.1 Single-stage crushing cubic metre (m3)
C4.1.7.2 Two-stage crushing cubic metre (m3)
C4.1.7.3 Multiple-stage crushing including screening cubic metre (m3)
C4.1.7.4 Screening only cubic metre (m3)
C4.1.7.5 Etc, for other plants (as stated by the Engineer and/or the Contractor) cubic metre (m3)
The unit of measurement shall be the cubic metre of material crushed or crushed and screened and finally used in the construction.
The quantity shall be measured in place in the compacted earthworks or pavement layers. The quantities shall not include excess material,
screened out material that is not used in the works, overfill material, or additional material placed for bulking (settlement during compaction).
The quantities for earthworks shall be measured from the difference between levelled cross sections at 20 m maximum intervals taken before and
after the construction of the earthworks.
The quantities for pavement layers shall be calculated from the authorised dimensions of the layers.
Where the materials are placed in stockpile for some time before used on the road, the Engineer and the Contractor shall agree on the interim
method of measuring the quantities for this item.
The tendered rates shall include full compensation for hauling the material from the excavation to the producing plant, for off-loading and producing
the material. The cost of loading the material at or in the excavation shall be included under item C4.1.5.
No haul shall be paid separately for moving material on the same borrow pit or quarry area. Hauling shall only be paid for material moved from
another borrow pit or quarry area than where the crushing and screening plant are located. Haul shall then be measured from the point where the
material is loaded to where it is off-loaded.
C4.1.8 Moving and re-erecting the crushing, screening and related plants on the site
C4.1.8.1 Single-stage crushing plant number (No)
C4.1.8.2 Two-stage crushing plant number (No)
C4.1.8.3 Multiple-stage crushing and screening plant number (No)
C4.1.8.4 Screening plant number (No)
C4.1.8.5 Etc, for other plants (as stated by the Engineer and/or the Contractor) number (No)

The unit of measurement shall be the number of times on a site that a plant is dismantled after its initial establishment on site (which is measured
and paid for under item C4.1.6), transported and re-erected, irrespective of the type of material produced.
The tendered rates shall include full compensation for dismantling the plant, loading, transporting, off-loading and re-erecting it at new positions,
and recommissioning it.
C4.1.9 Breaking down oversize material cubic metre (m3)

The unit of measurement shall be the cubic metre of oversize material that is broken down.
The quantity shall be measured by the volume of individual boulders or lumps of hard material. Where material is moved for breaking down the
Engineer may approve that the quantity be measured by taking the volume to be equivalent to 50 % of the loose volume in the haul vehicles of
the material to be broken down, as an alternative to measuring the individual volumes.
Breaking down of the material to the specified maximum particle sizes in Clause A4.1.7.2g) during the excavation operation in the borrow pits or
on the road by construction equipment shall not be measured in this item. Only further breaking down by conventional construction equipment of
oversize material in or at the borrow pit, as instructed or approved by the Engineer, shall be measured and paid.
The tendered rate shall include full compensation for breaking down the material.
No distinction shall be made between varies methods of breaking down the oversize material.
No haul shall be paid where oversize material must be moved for breaking down.
C4.1.10 Compacting the floor of the stockpile sites cubic metre (m3)
The unit of measurement shall be the cubic metre of compacted material.

The quantity shall be measured in place at the stockpile site, of the authorised area covered by the stockpile site.
The tendered rate shall include full compensation for scarifying, watering and compaction of the in situ material.
(Clearing and grubbing, and removal of topsoil if applicable, shall be measured and paid for under other items.)
C4.1.11 Constructing a platform for the stockpile site cubic metre (m³)
The unit of measurement shall be the cubic metre of compacted fill in the platform.
The quantity shall be measured in place at the platform, from the difference between levels taken after compaction of the stockpile floor and levels
taken after the construction of the platform.
The tendered rate shall include full compensation for excavating the material on the stockpile site or elsewhere on the borrow pit or quarry area,
moving or loading and hauling the material, for off-loading, and for placing, mixing, watering and compacting the fill material in the platform.
No difference shall be made between different types of fill material.
Any haul costs shall be included in the tendered rate of item C4.1.11.
C4.1.12 Stockpiling the material
C4.1.12.1 Material from a producing plant cubic metre (m3)
C4.1.12.2 Material directly from the excavation cubic metre (m3)
The unit of measurement shall be the cubic metre of material stockpiled.

The quantity for overburden shall be measured in place before stripping as specified under item C4.1.4.
The quantities for earthworks and pavement layers shall be measured in place in the compacted layers. The quantities shall not include excess
material, overfill material, or additional material for bulking.
The quantities for earthworks shall be measured from the difference between levelled cross sections at 20 m maximum intervals taken before and
after the construction.
The quantities for pavement layers shall be calculated from the authorised dimensions of the layers.
Where the materials are placed in stockpile for some time before used on the road, the Engineer and the Contractor shall agree on the interim
method of measuring the quantities for this item.
The tendered rate for item C4.1.12.1 shall include full compensation for loading the material at the producing plant, hauling the material to the
stockpile, off-loading, spreading and maintaining the material in the stockpile.
The tendered rate for item C4.1.12.2 shall include full compensation for hauling the material from the excavation to the stockpile, for off-loading,
spreading and maintaining the material in the stockpile. Loading the material at or in the excavation shall be measured under items C4.1.4 and
C4.1.5 respectively.
Payment for stockpiling of fill material directly from the excavation shall only be made when the Engineer has given prior approval for stockpiling
the fill material.

The temporary stockpiling of material within the borrow pit in heaps with a view to loading, or any other stockpiling method used in connection
with the loading method adopted by the Contractor in the borrow pit, shall not be classified as stockpiling for measurement under this item.
No additional measurement apart from this item shall be made for building up a stockpile in different layers for the purpose of mechanical
modification of pavement layers on the road.
No haul shall be paid separately for moving material within the same borrow pit or quarry area. Hauling shall only be paid for material moved to a
stockpile site not located at the same site as the producing plant (for item C4.1.12.1), or at another borrow pit or quarry area (for item C4.1.12.2).
Haul shall then be measured from the point where the material is loaded to where it is off-loaded.
C4.1.13 Removing surplus material from the stockpile cubic metre (m3)
The unit of measurement shall be the cubic metre of stockpiled material not used.
The quantity shall be measured in the haul vehicles by taking the volume to be the equivalent of 70 % of the loose volume of the material in the
haul vehicles.
The tendered rate shall include full compensation for loading and hauling the material to the borrow pit or the quarry or a designated site, for off-
loading and spreading the material.
Material shall be considered as surplus only when an instruction was given to stockpile the material or where the stockpile material was placed
by others. Removal of surplus material resulting from over production by the Contractor shall not be measured and paid.
designated site not at the same borrow pit or quarry area. Haul shall then be measured from the point where the material is loaded to where it is
off-loaded.
C4.1.14 Removing the fill platform and temporary banks at the stockpile sites upon completion
C4.1.14.1 Fill platform cubic metre (m3)
C4.1.14.2 Temporary banks cubic metre (m3)
The unit of measurement shall be the cubic metre of material removed.

The quantity shall be measured in place in the fill platform and the temporary banks, from topographical surveys. The Engineer may approve that
the quantity be taken as equal to 70 % of the volume of the loose material in the haul vehicles as an alternative to topographical surveys.
The tendered rates shall include full compensation for loading and hauling the material to the borrow pit or the quarry or a designated site, for off-
loading and spreading the material.
designated site not at the same borrow pit or quarry area. Haul shall then be measured from the point where the material is loaded to where it is
off-loaded.
C4.1.15 Shaping and finishing the borrow pit and quarry areas, and the stockpile sites
C4.1.15.1 Shaping and finishing the borrow pit and quarry areas, and the stockpile sites:
(a) Borrow pits (list all borrow pits separately) hectare (ha)
(b) Quarries (list all quarries separately) hectare (ha)
(c) Stockpile sites hectare (ha)
C4.1.15.2 Finishing of the borrow pit and quarry areas, and the stockpile sites using labour enhanced
methods of construction:
(a) Borrow pits (list all borrow pits separately) hectare (ha)
(b) Quarries (list all quarries separately) hectare (ha)
(c) Stockpile sites hectare (ha)
The unit of measurement shall be the hectare of area shaped and finished.
The quantities shall be measured from topographical surveys, measured in plan.
The tendered rates for borrow pits and quarries shall include full compensation for shaping and finishing the sides and floor of the excavation to
the specified slopes and gradients, forming smooth contours using soft material, placing of spoil or excess material in the floor and covering it,
removing all excess material, reconstructing temporary berms or constructing new berms, and final preparation of the slopes prior to the topsoiling
and revegetation operations.
Replacing overburden not used in the works in the borrow pit or quarry and levelling of the material are included in item C4.1.4.
The tendered rate for stockpile sites shall include full compensation for ripping and shaping the stockpile floor to the original contours.
Measurement and payment to remove any surplus material, the fill platform and the temporary banks shall be made under items C4.1.13 and

C4.1.14 respectively.
Distinction shall be made between the construction methods used.
Topsoiling and revegetation of the borrow pit and quarry area and stockpile sites will be measured and paid for under other items.
Any haul costs shall be included in the tendered rates of item C4.1.15.
C4.1.16 Personnel
C4.1.16.1 Materials manager month
C4.1.16.2 Excavation controller month
C4.1.16.3 Stockpile controller month
The unit of measurement shall be the time in month (or part thereof) that the respective personnel are employed on the contract to carry out the
specified duties.
The tendered rates shall include full compensation to cover the full cost of the respective personnel including all overhead charges and profit,
bonuses, subsistence, allowances, Contractor’s contributions, insurances, accomodation and vehicles for transport.
C4.1.17 Weighbridge facility
C4.1.17.1 Providing, erecting and removal of a weighbridge facility lump sum
C4.1.17.2 Operating the weighbridge month
The unit of measurement for item C4.1.17.1 shall be the lump sum.
The tendered rate for item C4.1.17.1 shall cover the cost for providing and erecting the weighbridge and the weighbridge office including all fittings,
for the power supply, and for providing and calibrating the scale equipment as specified and for the required computer hardware and software.
Payment of the item shall be made in two instalments:
• The first installment, 85 % of the lump sum, shall be paid after the weighbridge is commissioned.
• The final installment, 15 % of the lump sum, shall be paid when the weighbridge and office are removed from the contract.
The unit of measurement for item C4.1.17.2 shall be the time in months or part thereof that the weighbridge facility is operational and used for the
works.
The tendered rate for item C4.1.17.2 shall cover the cost for operating and maintaining the weighbridge, including the cost of the weighbridge
operator and all incidentals.
C4.1.18 Compensation to landowners or legal occupants in respect of land acquisition,

royalties and/or loss of crops
C4.1.18.1 Amount allowed, expenditure to be approved or instructed by the Employer provisional sum
WHERE CRUSHED STONE MATERIAL IS EXCAVATED, PRODUCED AND STOCKPILED FOR USE ON OTHER PROJECTS, THE ITEMS
HEREUNDER SHALL APPLY.
C4.1.19 Excavating hard material cubic metre (m3) or ton (t)
C4.1.20 Producing the material by
C4.1.20.1 Single stage crushing cubic metre (m3) or ton (t)
C4.1.20.2 Multi-stage crushing and screening cubic metre (m3) or ton (t)
C4.1.21 Stockpiling the crushed material cubic metre (m3) or ton (t)
The unit of measurement for every item shall be either of the following as specified in the Contract Documentation:
• The volume of loose material measured in the stockpile, or
• The mass of the material in the stockpile as determined by a weighbridge.
The tendered rate for item C4.1.19 shall include full compensation for excavating and loading the material.
The tendered rate for item C4.1.20 shall include full compensation for hauling the material from the excavation to the crushing plant, for off-loading
and producing the material.
The tendered rate for item C4.1.21 shall include full compensation for loading the material at the producing plant, hauling the material to the
stockpile, and for off-loading, spreading and maintaining the material in the stockpile.
crushing plant not located at the same borrow pit or quarry area from where the material is excavated, or where the stockpile site is not located at
the producing plant. Haul shall then be measured from the point where the material is loaded to where it is off-loaded.

D4.1 BORROW MATERIALS
CONTENTS
D4.1.1 SCOPE
D4.1.2 GENERAL

4.2 CUT MATERIALS
CONTENTS
A4.2.1 SCOPE
A4.2.2 DEFINITIONS
A4.2.3 GENERAL
A4.2.5 MATERIALS
A4.2.8 WORKMANSHIP

A4.2 CUT MATERIALS

A4.2.1 SCOPE
This Section covers the work requirements for sourcing natural or crushed materials that can be used for the construction of earthworks and road
pavement layers from:
• New cuttings.
• The widening of, or altering the side slopes of, or cutting of benches into existing cuttings.
• Box cuts for new roads and from box cuts for the widening of existing roads.
• Designated excavations.
Chapter 5 – Earthworks and Pavement layers: Construction, covers the construction of the road layers.
Specialised cutting slope protection measures are covered in Section 12.9 of Chapter 12.
A4.2.2 DEFINITIONS
The relevant definitions in Chapter 1 and Clause A4.1.2 shall also be applicable to this Section. Revised or additional definitions for this Section
are listed below.
Cuttings - are shallow or deep excavations made in the in situ material required for the construction of the road within the road reserve where the
road level results in a cutting slope or batter to be constructed and finished. Further or additional excavations, also referred to as under cuts,
below the road pavement layers to remove unsuitable stable material in the same excavation operation within the cutting shall be deemed part of
the cutting excavation.
Box cuts - are shallow excavations made in the in situ material required for the construction of the road pavement layers below the natural ground
level. Additional or further excavations, also referred to as under cuts, below the pavement layers to remove unsuitable stable material in the same
excavation operation within the box cut shall be deemed part of the box cut excavation. Box cuts are backfilled with the pavement layer, fill or with
other compliant material. Unlike cuttings and designated excavations, box cuts do not have side slopes that must be finished.
Cut material - any material excavated from cuttings, box cuts or designated excavations.
Designated excavations - are excavations for open drains and channels, canals including channels to direct the course of water flow, that can
yield compliant material for use in the works. The excavation criteria for open drains and channels to be classified as designated excavations are
provided in Table A3.1.7.2-1 of Chapter 3.
A4.2.3 GENERAL
A4.2.3.1 Employer requirements
The geotechnical information provided for the cuttings, box cuts and designated excavations reflects the results of site investigations including the
excavation of trial pits and/or drilling, and laboratory tests conducted by or on behalf of the Employer. This information is indicative of, but not
confirmation of, the sufficiency in quantity and quality of the material.

The Contractor shall use materials strictly in accordance with the requirements in the Contract Documentation and as instructed by the Engineer.
The Contractor shall ensure that compliant materials are not unnecessarily contaminated with non-compliant material and that cut materials are
not wasted.
All cuttings, and designated excavations where appropriate, must be surveyed and correctly staked before any cut operations commence to
ensure that the designated cut lines and slopes are adhered to.
The Contractor shall be instructed as to the applicable usage of the material supply always employing the best economic alternative (lowest
construction cost in terms of tendered rates) taking cognizance of the following:
• Quality of material,
• Haulage distance,
• Hardness of the material, and
• Overburden removal and use.
The Contractor shall not use cut material for any purpose other than the execution of this contract. Material shall not be disposed of, whether
processed or not, either by sale or donation to any person without the written authorisation of the Employer.
A4.2.3.2 Contractor prepared plans for cuttings

The Contractor shall prepare and submit a Management and Utilisation (M&U) plan of operations for every cutting where the quantity of cut
material will exceed 5 000 m3. Only a representative M&U plan can be submitted for cuttings between 5 000 m 3 and 10 000 m3 where the cuttings
have significantly similar material classes and excavation methods. Box cuts and designated excavations do not require M&U plans.
The M&U plan for the cutting shall at least show and include the following:
• The curriculum vitae of the proposed materials manager, excavation and stockpile controllers as applicable;
• The survey methods to stake the cut lines and slopes;
• Demarcation of the areas for stockpiling of topsoil, overburden and the various fill and pavement layer materials as required;
• Sequence and working of the cutting for sourcing the material;
• The testing protocol of the applicable tests and the frequency of testing;
• A method statement and risk assessment for sourcing the material;
• Method statements for the blasting of hard material, details for the safe storage and transport of explosives and the process for
obtaining blasting permits in terms of the requirements specified in Section A12.10 of Chapter 12;
• When blasting within the vicinity of buildings or structures, measures to comply with the relevant Act and Regulations pertaining to
the utilisation of explosives, as specified in Clause A1.2.7.5 of Chapter 1, proposals for the examination and recording of the condition
of the buildings and structures in Clause A1.2.3.13 of Chapter 1 and compliance with the specifications given in Clause A12.10.7.2
of Chapter 12;
• The finishing and stabilising of the cut slopes;
• The positioning of crushers, screens and other plant for crushing and screening of materials;
• Measures to comply with the conditions of the statutory road environmental approval;
• Measures to comply with safety regulations and obligations in terms of the relevant Health and Safety Acts and Regulations; and
M&U plans need only to be submitted during the course of the construction. However, no operations at a cutting including clearing and grubbing,
shall commence until the Contractor’s M&U plan for that cutting has been reviewed and accepted by the Engineer. The Engineer shall respond
within one week after receiving an M&U plan.

A4.2.5 MATERIALS
A4.2.5.1 General
The specifications given in Clause A4.1.5 shall also apply to cut materials and are the required specifications for the cut material as finally
processed and constructed on the road.

It is the Contractor’s responsibility to ensure that the cut material including all operations such as excavation, loading, hauling, producing and
stockpiling as applicable will comply with the material specifications, subject to the relevant provisions of the Contract Documentation.
Monitoring the quality and quantity of the cut materials produced for the construction on the road shall be the responsibility of the Contractor.
Based on a visual inspection by the Engineer and on the results of material tests as deemed appropriate, the Engineer shall have the right to
declare the material non-compliant for use at any time before construction on the road or stockpiling as applicable. The Contractor shall then
submit proposals for acceptance by the Engineer to rectify or replace the non-compliant material. Acceptance control testing of materials by the
Engineer shall only be carried out during or after construction on the road, or of the material in the stockpile as applicable.

Construction equipment to source the cut materials shall comply with the requirements of Clause A1.2.6 of Chapter 1.

A4.2.7.1 Excavation operations
a) Control at the cuttings, designated excavations and box cuts
Control at the cuttings and the designated excavations shall be done in accordance with the requirements in Clause A4.1.7.2a) for borrow pits
and quarries. Box cuts, being shallow excavations, do not require control of the excavation operations other than ensuring that the levels are
correct and the quality of the box cut material complies with its designated usage, and that the quantity and wastage aspects are controlled.
When there is at any time any doubt concerning the quality of the cut material for its intended use, the Contractor shall notify the Engineer
immediately before such material is brought onto the road or taken to stockpile. The results of all the tests conducted by the Contractor shall be
submitted. After further testing or inspection as required and agreed to, the Contractor shall be instructed regarding the further use of the cut
material.
When specified in the Contract Documentation, the Contractor shall have a full time or part time materials manager to conduct and manage the
duties for the control at the excavations. The requirements for the materials manager, whether the person shall be an engineering geologist,
engineer, a senior materials technician or a senior general foreman, and the required qualifications and experience of the materials manager,
shall then also be specified.
b) Classes of excavation
Excavation of material in a cutting, in a box cut and in a designated excavation shall be classed as soft, boulder or hard excavation in accordance
with the classification in Clause A4.1.7.2b).
In the absence of any construction equipment specified in the Contract Documentation to reference the efficient removal of soft material, the
following equipment, all construction equipment to be in good mechanical order, shall be used to determine the efficiency (production rates
hereunder refer to a continuous excavation production quantity of the in situ material):
• In road cuttings – a hydraulic crawler excavator with nett horsepower (flywheel power) generally between 180 kW and
225 kW, also known as a 30 ton excavator, and fitted with a heavy duty bucket. A minimum continuous production rate of 160 m3/h
of the excavated material will be taken as the benchmark for this excavator’s capacity and efficiency. When this production rate
cannot be achieved the material being excavated shall be classified as hard.
• In box cuts and designated excavations of large or medium size projects where larger excavators form part of the Contractor’s
approved construction equipment – a hydraulic crawler or wheel excavator with nett horsepower (flywheel power) generally between
100 kW and 150 kW, also known as a 20 ton excavator, and fitted with a general duty bucket for excavation of box cuts and with a
fish tail bucket for designated excavations. A minimum continuous production rate of 100 m3/h of the excavated material shall be
taken for this excavator’s capacity and efficiency. If this production rate cannot be achieved the material being excavated shall be
classified as hard.
• In box cuts and designated excavations of small projects where only small plant forms part of the Contractor’s approved construction
equipment, a tractor-loader-backhoe (TLB), or a small or compact excavator with nett horsepower (flywheel power) generally less
than 75 kW and fitted with a general duty or general purpose bucket. A minimum continuous production rate of 30 m3/h of the
excavated material shall be taken as the capacity and efficiency of a TLB or a small or compact excavator. When this production rate
cannot be achieved the material being excavated shall be classified as hard.
Excavation of material in existing roads of which the material is to be removed as part of the bulk excavation, shall also be classed in terms of this
Clause. When the existing road material is removed in controlled layers, the excavation classes in Section A4.3 shall apply.
The Contractor shall be at liberty to use any method and construction equipment for excavating any class of material, but the chosen method or
construction equipment to excavate the material shall not dictate the classification of the material.
Based on the information in the Contract Documentation, and further supplementary exploration during the contract as specified in Clause A4.2.7.1c),
and a visual inspection if possible, and before any excavation commences, the Engineer and the Contractor shall agree on the applicable classes of
excavation. Agreement shall also be reached on the method of measurement to be used for each class of excavation prior to the commencement of
any excavation.
In the event of a disagreement between the Engineer and the Contractor, the Contractor shall if required, make available such reference construction
equipment as specified at no cost to the Employer, in order to determine whether or not the material can be efficiently removed. The decision of the
Engineer as to the classification shall thereafter be final and binding, subject to the relevant provisions of the Contract Documentation.
The Contractor shall immediately inform the Engineer when the nature of the material being excavated changes to such an extent that a new
classification for further excavation is warranted. Failure to inform the Engineer of any possible change in the class of excavation before the material
is excavated, shall entitle the Engineer to classify and measure such excavation as deemed appropriate.
c) Supplementary exploration
The Contractor, in the presence of the Engineer, shall conduct further investigations and obtain information for the M&U plan of every cutting where
the quantity of cut material exceeds 5 000 m3, in accordance with the requirements of Clause A4.1.7.2c).
For smaller cuttings and box cuts the type of in situ material, the strength and indicator properties and the hardness of the material established during
the design stage, must be verified with further trial pits and subsequent laboratory testing.
Designated excavations will not usually have been investigated during the design stage of the project. If some geotechnical investigation results are
included in the Contract Documentation, it must only be regarded as indicative information that will require further confirmation. Supplementary
exploration comprising trial pits and material testing shall be conducted of every designated excavation to proof that the material is compliant for use
in the road or if it must be spoiled.

d) Clearing and grubbing
The top surface of a cutting, the widening or altering the side slope of an existing cutting, as well as the box cut and the designated excavation
surfaces shall be cleared and grubbed as specified in Section A1.6 of Chapter 1.
The extent of the clearing and grubbing for cut materials shall be as follows:
• In cuttings 1,0 m wider than the cut line, cut off bank or drainage dyke as applicable.
• For designated excavations 1,0 m wider on either side of the excavation cut line.
• For box cuts 0,5 m wider on either side of the excavation cut line plus a strip for any sidewalk, if applicable.
For clearing and grubbing of new developments in urban areas the Engineer shall instruct the extent of the clearing and grubbing, namely for the
full width of the road reserve or for only the width of the cutting or box cut as specified above.
In cuttings where the total thickness of the topsoil and the overburden is more than 1,0 m, all trees and tree stumps including mattered roots shall
be removed to a depth of at least 1,0 m below the cleared surface. Where the total thickness is less than 1,0 m a separate grubbing operation is
not required and the tree stumps can be removed together with the overburden, unless otherwise instructed by the Engineer.
In designated excavations and box cuts, trees and tree stumps including mattered roots shall be removed to 1,0 m below the cleared surface.
The removal of buildings and structures is specified in Section A1.6 of Chapter 1.
The removal of materials generally found in urban areas such as road edging, services structures, and paved sidewalks are specified in
Section 4.3.
e) Removal and conservation of the topsoil
After clearing and grubbing the topsoil shall be excavated and stockpiled as specified in Section A1.6 of Chapter 1, for later use in the works.
f) Spoil material
Material in the cuttings, the box cuts and the designated excavations that is not compliant for the earthworks and pavement layers or material that
is not required for further use shall be excavated, loaded and hauled directly to spoil sites. Only where designated spoil sites are not available at
the time of spoiling, shall temporary stockpiles be permitted with prior consent of the Engineer.
g) Cleaning of the bedrock
Hard rock material in the excavations to be processed by crushing or crushing and screening, shall be cleaned of all loose and foreign material
that may have remained from the topsoil and overburden, and that can affect the quality of the crushed rock.
h) Excavation of material in cuttings
The dimensions of cuts shall be in accordance with the details of the typical cross-sections as shown in the Contract Documentation, and shall
further be defined or amended during the course of construction by instructions from the Engineer. The Contractor shall first obtain instructions
from the Engineer regarding the slope of the sides of cuttings and the depth to which the cuttings are to be taken, including the dimensions of any
in situ treatment of cuts that may be required.
No removal of overburden or any further cutting operations shall commence until agreement has been reached with the Engineer in regard to the
thickness, the extent, use and quantity of the overburden. Overburden less than 200 mm thick shall be removed with the topsoil and not separately.
Overburden that is not required for further use shall be excavated, loaded and hauled directly to spoil sites. Only where designated spoil sites
are not available at the time of spoiling, shall temporary stockpiles be permitted with prior consent of the Engineer. Overburden required for later
use shall be moved to beyond the outer limits of the cutting. This operation shall not be regarded as temporary stockpiling. The Engineer’s approval
must be obtained for removing and stockpiling of overburden that cannot be moved to beyond the limits of the cutting, or for overburden that is to
be used in the works.
The Contractor shall take proper care when excavating material not to loosen any material outside the specified cut lines, whether by ripping,
blasting or by other means that would endanger the stability of the cutting slopes or that would subsequently cause undue erosion or disintegration
of the cutting slopes. This may entail modifying the methods of excavating when work is done in the vicinity of the final cut surface.
Care shall also be taken not to undercut any cutting slopes, and proper control shall at all times be exercised by regular survey checking and by
using batter poles at maximum 10 m intervals. The final surface of cuttings in hard excavation shall generally not be more than 0,5 m below the
specified cutting slope surface. Where the cutting slopes are nevertheless undercut and overbreak occurs, it shall be backfilled with imported
compacted gravel material, soil cement or concrete. Where the imported material may not be considered an appropriate remedy, remedial
measures may be ordered such as cutting back the entire or large sections of the cutting slope to a uniform slope, at the Contractor’s expense.
For excavations in hard material the Contractor shall design the drilling pattern, depth and explosive charge load according to the nature of the
material to achieve a stable cutting slope, at the specified slope with a minimum of overbreak. The Contractor shall not create loose unstable
material outside the specified cutting slope due to poor blasting or construction techniques. In such an event the Contractor shall render the
cutting slope stable by flattening or other approved methods at no cost to the Employer. When the nature of the material is such that an even
cutting slope cannot be achieved by blasting due to rock slope movement or boulders protruding from the slope that may become loose, the
Contractor shall inform the Engineer timeously that the overbreak is unavoidable and agreement shall be reached for compensation and backfilling,
if any, of the overbreak.
Specialised slope protection measures shall be specified in the Contract Documentation. These works shall be carried out in accordance with the
requirements and specifications in Section 12.9 of Chapter 12. When the Contractor is of the opinion that the nature or formation of the material
or rock in the cutting is too unstable to achieve the specified cutting slope or that the slope protection measures may be insufficient, the Engineer
shall be informed as soon as the unstable material becomes evident so that additional geotechnical measures can be implemented.
Benches shall be made in deep cuttings for maintenance and erosion prevention purposes, and in rock cuttings for stability purposes, in
accordance with details in the Contract Documentation.
The excavation of mudrock (shale) formations require special attention to minimise overbreak. On account of its poor durability qualities, mudrock
material from the excavation may not be appropriate for backfilling the overbreak and hence its use for this purpose may not be permitted.
The Engineer shall inspect the floor of the cutting as the bulk excavation proceeds, and shall instruct any additional deeper excavation to remove
unsuitable material.

The material in the cuttings shall be broken down to the following maximum particle sizes, depending on the use envisaged for the material, before
it is loaded:
• Pioneer material 500 mm.
• Rockfill 500 mm.
• Coarse fill 500 mm, but not exceeding the thickness of the fill layer for efficient compaction by the construction equipment.
• Normal fill 300 mm.
• Pavement layers 300 mm.
• Material to be crushed, the take of the crusher.
In order that the material can be broken down to the above-mentioned sizes, the Contractor shall adjust and control the blasting, ripping, excavating
and other operations so that the desired result can be achieved. Drilling and blasting patterns shall be such as to break down the material to the
specified sizes, and where this is impractical, secondary blasting or other methods shall be used for breaking down oversize materials.
Where the working methods of the Contractor are such that large quantities of oversize material are produced, the Contractor shall be instructed
to change the working methods, or type of crushing and screening plant, or construction equipment in order to produce less oversize material.
Excessive breaking down of the finer fraction of the material and thereby altering the properties of the material shall be avoided. Any material so
altered shall be replaced by the Contractor without any cost to the Employer.
When specified in the Contract Documentation, the Contractor shall have an excavation controller to manage the selection and excavation of the
cut material. The requirements for the excavation controller, namely whether the person shall be a materials technician or a general foreman, the
controller’s required qualifications and experience, and whether the controller is to be present full time or only part time at the excavation, shall
then also be specified.
i) Excavation of material in box cuts
The dimensions of box cuts shall be in accordance with the details of the typical cross-sections as shown in the Contract Documentation, and
shall further be defined or amended during the course of construction by instructions from the Engineer. The Contractor shall first obtain
instructions from the Engineer regarding the depth to which box cuts are to be taken, including any in situ treatment that may be required.
The sides of box cuts shall be stepped as shown in the Contract Documentation or as instructed by the Engineer. Where box cuts are made for
the widening of existing roads, the Engineer shall give instructions about the cut back and tie-in to the existing layers, and for saw-cutting of the
existing layers.
j) Excavation of material in designated excavations
Designated excavations shall be constructed true to line, grade and cross-section as shown to details in the Contract Documentation.
Excavation below the required grades shall be avoided, and any excavation beyond the required grade as a result of negligence or poor
construction techniques shall be backfilled with compliant material and compacted as approved by the Engineer, at no cost to the Employer.
For excavations in hard material, the Contractor shall plan the removal of the hard material so that it results in a minimum of or no overbreak.
k) Selection and use of the cut material
The results of laboratory tests, trial pits and drilling on cut materials carried out during the design stage are included in the Contract Documentation.
The results and other information in the Contract Documentation give a preliminary indication as to the purpose for which and where the cut
material shall be used. The Engineer shall give final instructions during construction regarding the use of the cut material.
Cut material shall be selected at the excavation, whether for use in the earthworks or in the pavement layers or in appurtenant works, so that its
usage is optimised. Compliant material shall not be excavated together with non-compliant material, unless it is impossible to separate the
different classes of material.
Cut to fill material shall be excavated and loaded directly for use on the road. Only after approval, where there is insufficient work space on the
road or where the excavation of the cut material cannot be postponed, shall the Engineer instruct that material be stockpiled temporarily. Material
placed temporarily adjacent to a trench or excavation for later loading and removal shall not be classified as stockpiling.
The cut material for pavement layers shall be selected, excavated, removed and always placed into suitable separate stockpiles to provide a
uniform material.
Coarse rock encountered shall be utilised for the construction of the lower layers of fills high enough to accommodate thick layers, or, where so
required, shall be conserved and used as directed for constructing the sides of embankments or for serving as protection against embankment or
channel erosion.
The Engineer may order that particular materials in road cuttings, box cuts and designated excavations be selected for a specific purpose. Where
selection is ordered, the method of excavation and the programme of works shall be so arranged by the Contractor to avoid double handling.
When ordered by the Engineer, the better class fill material shall be selected for use in the top layer of the fills and in the lower layers of high fills.
Any surplus or non-compliant material resulting from the excavations shall be disposed of as directed by the Engineer.
The Engineer shall have full control over the use of all cut material. The Contractor shall plan the operations and particularly the
cut-to-fill operations in such a manner that all cut material is used to the best advantage of the Employer. This means that no material shall be
unnecessarily spoiled, excavated, stockpiled or hauled. The Contractor shall neither excavate nor spoil any material without the Engineer’s
approval, and without proving to the Engineer that this is necessary and that it is the most economical method of constructing the works.
l) Use and treatment of oversize material
Excavated cut material that contains oversize material, that is material exceeding the specified maximum particle sizes in
Clause A4.2.7.1h), shall be handled as follows:
• Where the material contains less than 5 % by volume of the oversize material, the material can be hauled to the road or placed in
the stockpile. The oversize material shall then be broken down by using appropriate compaction rollers or bladed out of the layer or
removed by hand on the road, and then later returned to the borrow pit or taken elsewhere as spoil material or to a crusher, if
available, for crushing.

• Where the material contains more than 5 % by volume of oversize material the Engineer shall instruct before the material is loaded
at the excavation whether all the material, including the non-oversize material, shall be crushed and/or screened or broken down on
the road during construction or taken to spoil.
m) Producing the material by blasting, crushing and screening
The requirements for the control of blasting, and for producing material by crushing and screening of hard, boulder and oversize material in borrow
pits and quarries as specified in Clauses A4.1.7.2j) and A4.1.7.2k) respectively, shall also apply for cut material.
n) Finishing of the side slopes of cuttings and designated excavations
The side slopes of cuttings (batters) and designated excavations shall be finished (or shaped and formed) as specified in the Contract
Documentation or in the statutory road environmental approval. In the absence of any specified requirements, the minimum requirements listed
below shall be complied with for the finishing. Additional finishing requirements for specialised slope protection measures are given in Section
12.9 of Chapter 12.
The side slopes of road cuttings shall be finished (or shaped) as follows:
• The slopes shall be finished to a standard which is generally achievable with proper care and workmanship in the type of material
concerned. Care shall be taken not to undercut any side slopes which can cause sections to have a steeper slope than specified,
• Slopes at the junction of cuttings and fills shall be adjusted and evenly shaped so as to flow smoothly into the other or into the natural
ground without a noticeable break that can be readily discerned from the road,
• Slopes within soft material shall be finished to a slope not steeper than 1 vertical to 2 horisontal,
• In soft excavation all loose rocks, boulders and cobbles larger than 75 mm shall be removed and the final surface of the side slopes
shall have a slightly roughened surface where it is to be topsoiled,
• Slopes in soft excavation shall be finished to within a tolerance of 100 mm above to 100 mm below the specified side slope line, with
all undulations following a smooth line,
• Slopes in hard and boulder excavation shall be finished to remove all loose, unstable and unsafe material, and the slopes will
generally not require subsequent topsoiling and grassing,
• Finishing work shall include any measures specified in the Contract Documentation to protect and stabilise unstable slopes,
• Except in solid rock, the tops and bottoms of all side slopes shall be rounded for a width of 1,0 m,
• Where grassing is to be carried out the side slopes shall receive a 75 mm to 150 mm thick topsoil layer, and
• Cut off drains and/or banks shall be constructed at the top of all cut slopes where the natural ground above the cutting slopes towards
the cutting.
The finishing of the cutting slopes shall be completed prior to construction of the subbase layer.
The minimum requirements for finishing or shaping the side slopes of designated excavations are:
• The side slope shall be profiled to suit the specified dimensions and slopes of the structure for which the excavation has been made,
• All loose rocks, boulders and cobbles must be removed, as well as any protruding hard rock,
• Overbreak or over excavation shall be backfilled with stabilised material, soil cement or concrete,
• The surface of soft excavation shall be firm and loose material shall be compacted,
• Excavation lines for unlined designated excavations shall be finished to within a tolerance of 50 mm above to 50 mm below the
required levels, and
• Excavation levels for designated excavations that will receive a lining shall not be 25 mm higher or lower than the levels required for
the lining.
A4.2.7.2 Stockpiles
The preparation of the stockpile site, stockpiling of the material and reinstatement of the stockpile site shall be done in accordance with the
requirements of Clause A4.1.7.3.
Unless the material being obtained from cuttings, box cuts and designated excavations is very variable a full time stockpile controller is not
necessarily required.
A4.2.8 WORKMANSHIP
The Engineer and the Contractor shall determine and agree on the testing protocol and frequency of the applicable process control tests required
for each type of the sourced cut materials to ensure that the quality of materials produced meets the specified requirements for the particular layer
for which it will be used. These required laboratory tests and testing frequencies shall be stated in the cutting M&U plans.

B4.2 CUT MATERIALS
CONTENTS
B4.2.1 SCOPE
B4.2.2 DEFINITIONS
B4.2.3 GENERAL
B4.2.5 MATERIALS

B4.2.8 WORKMANSHIP
B4.2.1 SCOPE
This Section covers the sourcing of materials that can be used for the construction of earthworks and pavement layers from cuttings, box cuts and
designated excavations.
A relatively small proportion of activities as defined in Part A under the various Sections are considered suitable for labour enhancement.
B4.2.2 DEFINITIONS
Definitions as provided in Chapter 1 and Clause A4.2.2 shall apply.
B4.2.3 GENERAL

B4.2.5 MATERIALS


For Cut Materials, the shaping and finishing of the cutting faces are appropriate components for labour enhancement.
B4.2.8 WORKMANSHIP

C4.2 CUT MATERIALS
(i) Preamble
The following required activities will not be measured or paid for separately and the Contractor shall include the cost thereof in the items describing
the activity or in other items as deemed appropriate:
1. Excavation or undercut outside the specified dimensions or limits or the cutting slopes of the cuttings and excavations.
2. Backfill or cutting back the slope to remedy the overbreak or undercut that is caused by neglect, poor workmanship or inadequate supervision
and management by the Contractor.
3. Removal of any material that has become unstable due to the Contractor’s poor or inappropriate excavation and/or blasting methods, or any
work and materials required to remedy the unstable areas.
4. Spoil of oversize material due to poor blasting or construction techniques.
For activities in Table C4.2-1 items specified in other Sections of the specification, where they relate to work under this Section, will be listed in
the Pricing Schedule.
Clearing, grubbing, removal of large trees, and removal of

A4.2.7.1d) and A4.2.7.2 C1.6.1 to C1.6.4 of Chapter 1
buildings and structures
Conservation (excavating and stockpiling) of topsoil
A4.2.7e) C1.6.9 of Chapter 1
(including overburden less than 200 mm thick)
Blasting of hard material A4.2.7.1m) C12.10.1 of Chapter 12
Producing the material by crushing and screening A4.2.7.1m)
applicable items
Placing of topsoil, and vegetation A4.2.7.1n)
applicable items
Stockpiling the material A4.2.7.2
applicable items
Hauling material (when applicable) A4.2.7.1 and A4.2.7.2 C1.7.2 of Chapter 1

C4.2.1 Compiling and implementing M&U plans for the cuttings
C4.2.1.1 Cuttings exceeding 5 000 m3 up to 10 000 m3 number (No)
C4.2.1.5 Cuttings larger than 100 000 m3 number (No)
The volume referred to in the description shall be the total volume of material in place that must be removed. It includes the volume of topsoil and
overburden, the material compliant for earthworks and pavement layers and any spoil material.
The unit of measurement shall be the number of cuttings for which M&U plans have been compiled. A distinction shall be made between the
various cuttings based on the total volume of material to be excavated in the cutting. When several cuttings between 5 000 m3 and 10 000 m3 are
covered by a representative M&U plan they shall all be measured together as one plan.

The tendered rates shall include full compensation for gathering all information and compiling the plans, except for the additional material
investigations agreed to by the Engineer that will be measured and paid separately, and to ensure implementing the plans during the operation of
the cutting.
C4.2.2 Additional material investigations during the supplementary exploration
C4.2.2.1 Cost of additional trial pits and/or drilling and laboratory testing provisional sum
C4.2.3 Excavating of materials in cuttings, material obtained from
C4.2.4 Excavating of materials in box cuts, material obtained from
C4.2.5 Excavating of materials in designated excavations, material obtained from
The unit of measurement for items C4.2.3, C4.2.4 and C4.2.5 shall be the cubic metre of material excavated for use on the road.
The volume shall be measured in place in its original position in the cutting, box cut or designated excavation. It shall be calculated from the
difference between levels taken or topographical surveys carried out after the removal of the topsoil, and from levels taken or surveys done after
completion of the excavation of the different material classes. The volume of classified unavoidable overbreak in hard or boulder material shall be
included in the measurement.
For boulder material, the Engineer may approve that the quantities be measured in haul vehicles as an alternative when the boulder material
cannot be identified accurately prior to excavating, by taking the in situ volume of the boulder material as equal to 50 % of the loose volume of the
material in the haul vehicles.
The tendered rates for items C4.2.3, C4.2.4 and C4.2.5 shall include full compensation for breaking down the cut materials in the various classes
to the specified maximum particle sizes, for excavating, and loading the material. Should the Contractor choose for designated excavations to
temporarily place the excavated material next to the excavation for loading later, it shall not be considered as stockpile of material nor shall the
loading be considered as a separate activity for compensation.
The excavation of hard material by blasting shall exclude the cost of blasting, which shall be measured and paid for under item C12.10.1 of
Chapter 12.
The excavating and disposing of unsuitable and spoil material shall be measured and paid for under item C4.2.7 and under item C4.2.8 or C4.2.9
as applicable.

C4.2.6 Widening of existing cuttings
The unit of measurement shall be the cubic metre of material excavated during the widening of existing cuttings.
Widening of existing cuttings shall be a widening more than 2,5 m deep (measured vertically from the top of the cutting to the shoulder breakpoint),
and where the cutting is widened by less than 4,0 m. Widenings of existing cuttings larger than these dimensions shall be measured and paid for
under item C4.2.3.
Measurement of the material shall be in place in the original position in the cutting, and the quantity shall be computed by the method of average
end areas from surveyed cross-sections at intervals not exceeding 20 m measured along the centre line of the road or from topographical surveys,
before and after removal of the material.
For boulder material, the Engineer may approve that the quantities be measured in haul vehicles as an alternative when the boulder material
cannot be identified accurately prior to excavating, by taking the in situ volume of the boulder material as equal to 50 % of the loose volume of the
material in the haul vehicles.
The tendered rates shall include full compensation for breaking down the various classes to the specified maximum particle sizes, excavating, and
loading the material.
Chapter 12.
C4.2.7 Removal of unsuitable stable cut material to spoil
C4.2.7.1 In layer thicknesses of 200 mm and less cubic metre (m3)
C4.2.7.2 In layer thicknesses exceeding 200 mm cubic metre (m3)
The unit of measurement shall be the cubic metre of material removed to spoil in accordance with the Engineer’s instructions.
The volume shall be measured in place in its original position and shall be calculated in accordance with the authorized dimensions.
The tendered rates shall include full compensation for excavating and loading the material in the floor of the excavation, and for disposing the
material. Payment under this item shall only be made when the material is removed in a separate excavation operation after the bulk excavation
is completed on instruction by the Engineer, else the material shall be classified as spoil material and then measured and paid for under item
C4.2.8 or C4.2.9 as applicable.
Haul shall be measured from the point where the material is loaded to where it is off-loaded.
C4.2.8 Excavate material to spoil in sites designated by the Employer, material obtained from
C4.2.8.1 Soft excavation, overburden and unsuitable material cubic metre (m3)
The unit of measurement shall be the cubic metre of material excavated and spoiled.
The quantities shall be measured in place in its original position in the cutting, box cut or designated excavation, and shall be computed from
topographical surveys. The Engineer may approve that the quantities be measured in the haul vehicles as an alternative when the quantities of
the spoil material cannot be calculated accurately prior to excavating, by taking the in situ volume of the material in the case of soft excavation as
equal to 70 % of the loose volume of material in the haul vehicles, and in the case of boulder and hard material as equal to 50 % of the loose
volume of material in the haul vehicles.
The tendered rates shall include full compensation for breaking down the various classes to sizes required for hauling, excavating and loading,
and for off-loading and disposing the material, including shaping and levelling-off any heaps of spoil material.

Chapter 12.
C4.2.9 Excavate material to spoil in sites designated by the Contractor, material obtained
from
C4.2.9.1 Soft excavation, overburden and unsuitable material cubic metre (m3)
The unit of measurement shall be the cubic metre of material excavated and spoiled.
The quantities shall be measured in place in its original position in the cutting, box cut or designated excavation, and shall be computed from
topographical surveys. The Engineer may approve that the quantities be measured in haul vehicles as an alternative when the spoil material
cannot be identified accurately prior to excavating, by taking the in situ volume of the material in the case of soft excavation as equal to 70 % of
the loose volume of material in the haul vehicles, and in the case of boulder and hard material as equal to 50 % of the loose volume of material in
the haul vehicles.
The tendered rates shall include full compensation for negotiations with the landowner or legal occupant of the property or of the spoil site, for
breaking down the various classes to sizes required for hauling, excavating, loading and hauling the material to the spoil sites irrespective of the
haul distance, for off-loading and disposing the material, and for finishing the spoil site and obtaining the approval of the property or spoil site
owner, if applicable.
Chapter 12.
The tendered rates shall also include the cost of spoiling at a municipal site, if applicable.
All haul costs shall be included in the tendered rates of item C4.2.9.
C4.2.10 Backfilling of the unavoidable overbreak in hard and boulder excavation
C4.2.10.1 Compliant gravel material cubic metre (m3)
C4.2.10.2 Soil cement (stiff mix with 3 % cement) cubic metre (m3)
C4.2.10.3 Soil cement (wet mix with 5 % cement) cubic metre (m3)
C4.2.10.4 Concrete class 15 MPa cubic metre (m3)
The unit of measurement shall be the cubic metre of material used in the backfilling.
The quantities shall be measured from the quantity of material placed in the overbreak.
The tendered rates shall include full compensation for providing the material, and for placing, backfilling and compacting the material in the
overbreak.
Payment for backfilling of overbreak shall only be made when the Engineer approves that the overbreak was unavoidable.
C4.2.11 Breaking down oversize material cubic metre (m3)
The unit of measurement shall be the cubic metre of oversize material that is broken down.
The quantity shall be measured by the volume of individual boulders or lumps of hard material. Where material is moved for breaking down the
Engineer may approve that the quantity be measured by taking the volume to be equivalent to 50 % of the loose volume in the haul vehicles of
the material to be broken down, as an alternative to measuring the individual volumes.
Breaking down of the cut material to the specified maximum particle sizes in Clause A4.2.7.1h) during the excavation operation or on the road by
construction equipment shall not be measured under this item. Only further breaking down by conventional construction equipment of oversize
cut material, as instructed or approved by the Engineer, shall be measured and paid.
The tendered rate shall include full compensation for breaking down the material.
No distinction shall be made between varies methods of breaking down the oversize material.
No haul shall be paid where oversize material must be moved for breaking down.

C4.2.12 Finishing the side slopes
C4.2.12.1 Cuttings:
(a) In soft material square metre (m2)
(b) In boulder material class A and B square metre (m2)
(c) In hard material square metre (m2)
(d) In soft material using labour enhanced methods of construction square metre (m2)
C4.2.12.2 Designated excavations square metre (m2)
C4.2.12.3 Designated excavations using labour enhanced methods of construction square metre (m2)
The unit of measurement for cuttings shall be the square metre of the finished side slope areas.
The unit of measurement for designated excavations shall be the square metre of the side slope areas and the floor (invert) area where applicable.
The areas shall be measured from topographical surveys, or from tape measurements at 5,0 m cross section intervals where accurate tape
measurements can be undertaken.
The tendered rates for finishing shall include full compensation for finishing the side slopes, and for loading, hauling and disposing of any excess
material arising or brought down during the finishing operations. Placing of topsoil and vegetation shall be measured and paid separately.
Specialised slope protection measures shall be measured and paid in Section 12.9 of Chapter 12.

D4.2 CUT MATERIALS
CONTENTS
D4.2.1 SCOPE
D4.2.2 GENERAL

4.3 EXISTING ROAD MATERIALS
CONTENTS
A4.3.1 SCOPE
A4.3.2 DEFINITIONS
A4.3.3 GENERAL
A4.3.5 MATERIALS
A4.3.8 WORKMANSHIP

A4.3 EXISTING ROAD MATERIALS

A4.3.1 SCOPE
This Section covers the work requirements for sourcing of existing road construction materials that are:
• Obtained from reclaiming or from the reconstruction of existing road fills, pavement layers and asphalt materials.
• Used to reconstruct the same road they are obtained from or used on another road project.
This Section also covers the removal of existing concrete pavements and paving blocks from the road, and of materials in urban areas such as
road edging, services structures, and paved sidewalk materials.
A4.3.2 DEFINITIONS
The relevant definitions in Chapter 1 and Clause A4.1.2 shall also be applicable to this Section. Additional definitions for this Section are listed
below.
Cemented material - also referred to as bound material, is existing stabilised or treated road layer material that can only be removed by milling,
or by pulverising prior to excavation by using conventional road construction equipment.
Milling - a process to break down (pulverise) and remove, all or part of bituminous surfacing layers (seals and asphalt), and/or pavement layers
by a milling machine.
Reclaimed road materials - are obtained by breaking up and excavating material in controlled separate layers from the existing earthworks and
pavement layers and bituminous surfacing layers, producing compliant material by crushing and/or stockpiling it if required, and then hauling or
moving it for use elsewhere on the same road, or on another road project or for other construction purposes.
Reconstructed road materials - are existing layer and bituminous surfacing materials that are scarified or pulverised (broken down) by ripping
or broken down by a recycling machine and then subsequently processed in situ, for the construction of reconstructed road pavement layers.
A4.3.3 GENERAL
A4.3.3.1 Employer identified existing road materials
The road layer information provided in the Contract Documentation for the existing layers reflects the results of trial pits and laboratory tests
conducted by or on behalf of the Employer. This information is indicative of the type of road layer materials and layer thicknesses. The provision
of this information shall not in any way be construed as defining or limiting the extent and thickness of materials nor the quality to be obtained
from the existing road.

The use of existing road materials shall be specified in the Contract Documentation. These materials could be re-used on their own or mixed and
blended with additional imported material or used with material from underlying layers or a combination of the above in order to increase the new
layer thickness, or improve the material properties, or a combination of both requirements for the intended use of the material in the road.
A4.3.3.2 Contractor identified materials

Should the Contractor wish to propose alternative reclaiming or recycling methods, or use different materials or different proportions of materials,
then a method statement shall be provided by the Contractor. The method statement shall be supported by sufficient test results and shall confirm
that the Contractor’s proposal will meet the Employer’s requirements. When accepted, the Contractor‘s alternative methods and/or identified
materials shall then be handled as an alternative in terms of the conditions of contract.

A4.3.5 MATERIALS
A4.3.5.1 Reclaimed and reconstructed gravel and crushed stone materials
The specifications given in Clause A4.1.5 for the materials shall also apply to reclaimed and reconstructed gravel and crushed stone materials.
The material requirements for stabilised materials are given in Table A4.4.5-2, and for bitumen stabilised materials in Table A4.4.5-3.
These material specifications are the required specifications for the reclaimed or reconstructed material finally processed and constructed on the
road. The Contractor may be instructed to modify or blend reclaimed or reconstructed material by the addition of some imported material and/or
treatment agents in order to produce a material that complies with the specified material properties.
A4.3.5.2 Reclaimed asphalt material

Asphalt material from existing surfacing or base layers may be removed to spoil or reclaimed for use.
Reclaimed asphalt from a surfacing and/or base layer may be used in the construction of earthworks, new pavement layers, recycled pavement
layers or placed on the road shoulders. It may also be used as reclaimed asphalt in new asphalt layers, or for a wearing course of an unsealed
road. The Contract Documentation shall specify where and in what mix proportions, if any, the reclaimed asphalt shall be used.
A4.3.5.3 Bituminous seal surfacings

Thin bituminous seal surfacings shall be processed together with the underlying layer during reconstruction, or shall be removed by blading or
milled off before being taken to spoil, or shall be treated as reclaimed material if compliant for further use as specified in the Contract
Documentation or instructed by the Engineer.

It is the Contractor’s responsibility to ensure that the processed reclaimed or reconstructed materials resulting from all operations such as milling,
pulverising, excavating, stockpiling, loading and hauling operations as applicable shall comply with the required material specifications, subject to
the relevant provisions of the Contract Documentation.

A4.3.6.1 General
Construction equipment to source the existing road materials shall comply with the requirements of Clause A1.2.6 of Chapter 1.
A4.3.6.2 Milling machine

The milling machine shall be capable of milling out either bituminous surfacing layers or unstabilised/stabilised pavement layer materials, or a
combination of both simultaneously, to the depth specified in the Contract Documentation or as instructed by the Engineer.
The direction and speed of the milling machine and the speed of rotation of the milling drum shall be adjustable to deliver the required material
properties. The machine shall be capable of making a neat vertical cut at the outer edges when milling. The Contractor shall inspect the milling
machine’s cutting tools, also known as picks, regularly and replace them as required whenever uneven or ineffective milling occurs, or when the
gradation of the milled material is adversely affected.
The milling machine shall be equipped with a self-loading conveyor belt which can be easily removed and installed, and adjusted for slope and
direction.
A4.3.6.3 Construction equipment for breaking down and excavation

The type of construction equipment to be used for the breaking down and excavation of existing pavement layers shall be determined by the size
and depth of the pavement section to be excavated, taking into consideration that the work is sometimes carried out in restricted areas confined
to only the demarcated areas of the pavement layers to be broken up.

A4.3.7.1 Reconstructed layers
The construction of reconstructed layers, including the breaking down and/or pulverising of the layers and then reconstructing it with or without
modification, is covered in Section 5.5 of Chapter 5.
A4.3.7.2 Supplementary exploration

The Contractor, in the presence of the Engineer, shall conduct further investigations to confirm the quality, thickness, properties and quantity of
the material of the existing road layers, that have been identified for reclaiming or reconstruction in the Contract Documentation.
Where it is intended to separately remove the asphalt layers in the existing pavement, investigations shall be carried out to determine the following:
• Potential quantity of the asphalt available for reclaiming,
• The haul distance to the nearest asphalt mixing plant with recycling capability,
• Locating a suitable area for stockpiling the reclaimed asphalt to suit the future recycling on other projects if applicable,
• Basic asphalt mix types in the existing pavement,
• Uniformity of the asphalt in the existing pavement layers,
• Visual condition of the pavement, and
• Ownership of the reclaimed asphalt.
Samples of asphalt layers shall be taken by at least 150 mm diameter cores or by using a small milling machine. The asphalt material shall be
examined to establish:
• The thickness of each asphalt layer found in the core or in the excavation side face,
• The asphalt mix types in single or multiple layers,
• The presence of surfacing seals, particularly those containing highly modified binders,
• The presence of coal tar that can normally be detected by its pungent odour, and that will classify the material as hazardous and
non-compliant for use as reclaimed asphalt,
• The presence of geosynthetic or other types of asphalt reinforcement interlayers, and
• For signs of stripping of the binder from the aggregate.
Trial pits in the road layers, or coring in cemented layers shall be made to depths as instructed by the Engineer. Sufficient trial pits or coring shall
be made so that uniform material sections can be identified.
A4.3.7.3 Classes of excavation for reclaimed material

The classes of excavation of reclaimed material shall be classed according to the type of material being reclaimed, namely:
• Asphalt material, including bituminous surfacing seals thicker than 30 mm.
• Crushed stone and macadam materials.
• Cemented (chemically stabilised) material.
• Natural gravel and sand materials in the pavement layers and earthworks.
• Coarse and rock fill materials.
The removal of road material not excavated in controlled layers shall be classed as for box cuts and designated excavations in terms of Clause
A4.2.7.1b) in Section 4.2.
A4.3.7.4 Milling
Before milling may be commenced, the surface of the existing road shall be cleaned of all vegetation, dirt, recent fuel spillage, road studs and any
other foreign material.
Where the milled material is to be re-used in road pavement layers, the Contractor shall execute trial milling on the various materials to be milled.
Trial milling shall consist of milling one strip not longer than 40 m. Trial milling shall not be required for material that is to be milled to spoil or
re-used for general filling purposes. During the trial milling, the Contractor shall vary the speed of the milling machine, the speed of rotation of the
milling drum and the milling depth, to select the desired optimum milling operation parameters to provide the required material quality and to prove
that the milling machine is fit for purpose. The Engineer shall instruct the depth of milling the layer(s) after the trial milling.
Care shall be exercised to avoid damage to any concrete elements such as bridge expansion joints and joint nosings, manholes, kerbing, kerb
inlets and any other roadside furniture during the milling and the excavation. Damage caused to any element forming part of the permanent works
shall be repaired at no cost to the Employer.
The floor of a milled excavation shall have an even texture without any loose local areas. Loose areas shall be remedied as specified in the
Contract Documentation or as instructed by the Engineer.
The floor of a milled excavation shall be tested in the longitudinal direction with a 3,0 m straight-edge, and in other directions with a straight-edge
of such length as fits between the longitudinal sides of the excavation. The surface of the milled area shall not deviate by more than
7,0 mm from the bottom edge of the straight-edge.

A4.3.7.5 Safety at milled excavations
Milled excavations shall not be trafficked unless it is necessary to temporarily accommodate traffic. When shallow milled excavations need to be
opened to traffic then all loose material shall first be removed, and all longitudinal and transverse joints caused by the milling excavation shall be
tapered where the difference in level between the floor of the milled excavation and the existing road surface exceeds 25 mm. Transverse joints
shall be tapered at a slope of 1,0 mm vertical to 20,0 mm horisontal. Longitudinal joints shall be tapered at a slope of 1,0 mm vertical to 5,0 mm
horisontal. The tapers shall either be formed by cutting back the joint edges to the specified slope or by constructing a suitable asphalt wedge,
which shall be bonded to the cleaned joint with a bituminous bond coat.
A4.3.7.6 Removal of asphalt material

Reclaimed asphalt material shall be removed separately from the existing road, either by excavating and breaking down the asphalt material into
blocks using conventional road building equipment, or by milling off the asphalt material.
Where only part of the asphalt is to be milled off, the area to be milled shall be demarcated and the milling depth shall be specified. Milling shall
not exceed the demarcated width by more than 50 mm or the specified depth by more than 5,0 mm.
Where the asphalt consists of layers of various mixes or grades, the results of the supplementary investigation will assist in deciding on the most
appropriate milling strategy, namely whether to mill different asphalt layers separately (split milling), or to mill multiple asphalt layers together, or
selective milling of non-compliant layers that must be discarded.
Contamination of the asphalt with underlying material, or unwanted damage to the underlying layer, during milling shall be avoided. The Contractor
shall adjust and carefully control the depth of milling to prevent this by full time monitoring of the milled floor behind the milling machine.
Where the material is contaminated by the actions of the Contractor, it shall be replaced with other approved material at no cost to the Employer.
A4.3.7.7 Excavation of crushed stone, macadam, cemented and gravel materials

The existing pavement material shall be ripped or pulverised to the specified depth and then excavated using conventional road building equipment
or by milling. The underlying layers shall not be damaged. Different types of material in consecutive layers may not be mixed unless required,
and the Contractor shall adjust the depth of ripping, pulverising or milling in accordance with the thickness of the layer. Continuous adjustment
will be required to suit any variations in the thickness of the pavement layer. Where unauthorised mixing occurs or where the material is
contaminated in any other way by the actions of the Contractor, it shall be replaced with other approved material at no cost to the Employer.
Where a layer or layers required to be excavated over part of the road width only, the limit of the work shall be clearly demarcated and shall not
be exceeded by more than 100 mm. Saw-cutting along the demarcated setting out line prior to excavation is obligatory, except where the material
is removed by milling.
Excavation outside the demarcated limits shall be repaired by the Contractor at no cost to the Employer.
When specified in the Contract Documentation, the Contractor shall have an excavation controller to manage the selection and excavation of the
pavement materials. The requirements for the excavation controller, namely whether the person shall be a materials technician or a general
foreman, the controller’s required qualifications and experience, and whether the controller is to be present full time or only part time at the
excavation of the reclaimed pavement materials, shall then also be specified.
A4.3.7.8 Removal of existing concrete

The thickness of existing concrete road pavements or paving shall be established by core drilling prior to removal. Sidewalk or driveway concrete
pavements do not need to be cored.
The existing concrete shall be removed by one of two methods:
• The break-up method, or
• The lift-out method.
The break-up method comprises breaking of the concrete with hand operated pneumatic or electro-mechanical equipment such as jackhammers
or pavement breakers, or high energy impact compaction rollers, and removing it with a front end loader or a tractor-loader-backhoe (TLB) or by
labour enhanced methods. Breaking out may be assisted by additional intermediate saw-cuts. In road pavements the breaking operation shall
commence from the centre of the concrete pavement towards the boundary saw cuts to eliminate damage to any adjoining slabs. Care shall be
taken with this method to avoid damage to the subbase if it is not to be reclaimed or recycled.
The lift-out method requires lifting hooks to be attached to the saw-cut slab and heavy lifting plant to lift out the concrete. Alternatively, the slab
may be sawn into smaller pieces so that it can be lifted out by a front end loader or TLB. Although this method is less likely to damage the subbase
and adjacent slabs, the Contractor is required to dispose of large slabs of concrete.
Where concrete is to be removed over part of the road width only, the limit of the work shall be clearly demarcated. Saw-cutting along the
demarcated setting out line is obligatory. Removal of existing concrete outside the demarcated limits shall be repaired by the Contractor at no
cost to the Employer.
A4.3.7.9 Removal of existing paving blocks

Existing paving blocks shall be lifted and used as specified in the Contract Documentation and/or instructed by the Engineer. Paving blocks that
are to be handed to a property or landowner or are to be stockpiled for re-use shall be lifted by hand only. Paving blocks removed to spoil can be
lifted by construction equipment.
Where paving blocks are to be handed to a property or landowner, the Contractor shall mark paving blocks that are broken or chipped and indicate
them to the property or landowner prior to lifting of the blocks. The blocks shall be neatly stacked in a location agreed with the owner.
Paving blocks marked or instructed by the Engineer for re-use or other purposes, shall be removed to stockpile, and then neatly stacked.
Paving blocks that must be handed to a property or landowner, or that will be stockpiled for re-use, shall be cleaned of dirt, soil, concrete spillage
and the like.
The bedding sand shall be removed after lifting of the paving blocks.

A4.3.7.10 Removal of the existing road edging
Existing road edging, such as in situ concrete kerbing and edge beams, precast kerbing, kerb inlets (catchpits), grid inlets and so forth, shall be
demolished and removed to spoil at an approved spoil site provided by the Contractor, or shall be stockpiled and stacked for re-use as instructed
by the Engineer.
A4.3.7.11 Saw-cutting
When specified or instructed that existing pavement layers are to be saw-cut, the equipment shall be capable of saw-cutting the pavement layers
in a single operation without fragmenting the material, and in straight lines. The depth of saw-cutting shall be specified in the Contract
Documentation or instructed by the Engineer. Requirements for saw-cutting and the construction of joints between existing and new layers are
specified in Clause A5.3.3.7 of Chapter 5.
A4.3.7.12 Stockpiling of material

Should the reclaimed material have to be stockpiled, the requirements for stockpiles in Clause A4.1.7.3 shall apply. Stockpile sites shall be large
enough to allow the placing of different types of material without the stockpiles overlapping.
a) Preparation of the stockpile site
Stockpile sites shall be prepared in accordance with the requirements of Clause A4.1.7.3a).
When specified in the Contract Documentation or instructed by the Engineer, the floor for the reclaimed asphalt stockpile site shall be stabilised
to a depth of 150 mm.
b) Stockpiling of the material
Different types of material shall be stockpiled separately. When instructed by the Engineer, the Contractor shall remove the reclaimed asphalt
material obtained from split milling to separate stockpiles.
Stockpiles of unprocessed reclaimed asphalt shall be ramp shaped and lifted in layers. When flattening the tipped material, it shall not be pushed
over the edge to cause segregation. Stockpiles of unprocessed reclaimed asphalt shall not be covered, except when instructed by the Engineer.
Additional stockpiling requirements for reclaimed asphalt and for stockpiling of pavement layer materials are listed in Clause A5.5.5.2 of
Chapter 5.
A4.3.7.13 Spoil of material

Material from the milling and/or excavations of existing road materials that is non-compliant for the earthworks and pavement layers or material
that is not required for further use shall be loaded and hauled directly to approved spoil sites.
Paving blocks, and road edging not suitable for further use or that are not required in future construction shall be loaded and hauled to approved
spoil sites. Services structures, and asphalt and concrete material on sidewalks in urban areas shall also be spoiled.
Spoil sites are to be identified by the Employer or by the Contractor.
A4.3.8 WORKMANSHIP
The material properties of the existing road layers shall always be verified by drilling of cores or by additional trial pits in the road and by subsequent
laboratory testing, before any milling and/or excavation is carried out. The depths of the core drilling and trial pits and applicable laboratory tests
shall be determined by the intended use of the material in the existing road, whether the material is to be reclaimed or recycled.
Testing shall be more comprehensive for recycling of layers. The effects of patching and repairs, the variable thickness of layers and the variable
addition of new material may result in the fluctuation of material properties. The impact of the fluctuation of these properties must be properly
managed.
For the recycling of asphalt and/or bound (stabilised) materials, slabs of the materials shall be removed from the road trial pits and then crushed
manually or with a small laboratory crusher to simulate the material produced by the recycler.
Agreement shall be reached with the Engineer on the testing, protocol of the applicable tests and frequency of process control testing on the
existing road materials, to ensure that the quality of the materials meets the specified requirements for the particular layer for which it will be used.

B4.3 EXISTING ROAD MATERIALS
CONTENTS
B4.3.1 SCOPE
B4.3.2 DEFINITIONS
B4.3.3 GENERAL
B4.3.5 MATERIALS

B4.3.8 WORKMANSHIP
B4.3.1 SCOPE
This Section covers existing road construction materials that are obtained from reclaiming or reconstructing existing road earthworks, pavement
layers and asphalt materials (whether used as a pavement layer or used as the wearing course).
A relatively small proportion of activities as defined in Part A under the various sections are considered suitable for labour enhancement. Therefore,
Part B only provides additional specifications not contained in Part A.
B4.3.2 DEFINITIONS
Definitions as provided in Chapter 1 and Clause A4.3.2 apply.
B4.3.3 GENERAL

B4.3.5 MATERIALS


For existing road materials, the excavation of reclaimed material, the removal of existing paving blocks, the removal of existing road edging and
the spoil of material from gravel or crushed stone layers are appropriate components for labour enhancement.
B4.3.8 WORKMANSHIP

C4.3 EXISTING ROAD MATERIALS
(i) Preamble
Any prime cost or provisional sums shall be paid in accordance with the provisions of the Conditions of Contract. The charge or mark-up tendered
Loading of the reclaimed material on the existing road and hauling it for use elsewhere shall be measured in Chapter 5.
There are no activities in Section A4.3 that will not be measured and paid separately and for which the cost must be included in other items.
(iii) Items to be measured and paid for using items elsewhere in the specifications
For activities in Table C4.3-1 items specified in other Sections of the specification, where they relate to work under this Section, will be listed in
the Pricing Schedule.
Producing the material by crushing and screening A4.3.2 Section C4.1 - All applicable items
Loading material C4.3 C1.7.1 of Chapter 1
Hauling material (when applicable) A4.3.7.11 and A4.3.7.12 C1.7.2 of Chapter 1
Stabilising the floor of reclaimed asphalt material stockpile sites A4.3.7.11 C5.4.2 of Chapter 5
C4.3.1 Additional material investigations
C4.3.1.1 Cost of additional core drilling and trial pits, sampling of asphalt and laboratory testing provisional sum
C4.3.2 Cleaning the existing road surface
C4.3.2.1 Cost to clean the road surface provisional sum
C4.3.3 Removal of bituminous seal surfacing (thickness not exceeding 30 mm) square metre (m2)
The unit of measurement shall be the square metre of seal surfacing removed separately.
The quantity shall be measured from the authorised dimensions.
The tendered rate shall include full compensation for blading or milling off the existing seal surfacing, and for loading and hauling the material to
spoil sites identified by the Contractor.
All haul costs shall be included in the tendered rate of item C4.3.3.
The removal of a bituminous seal surfacing together with the underlying base layer shall not be measured in this item, but the cost shall be included
with the excavation of the base layer under items C4.3.9 and C4.3.10 respectively.

C4.3.4 Saw-cutting existing materials within the following average depth ranges
C4.3.4.1 Asphalt material:
(a) Up to 50 mm metre (m)
(b) Exceeding 50 mm and up to 100 mm metre (m)
(c) Etc, in 50 mm increments
C4.3.4.2 Crushed stone and gravel material:
C4.3.4.3 Cemented material:
C4.3.4.4 Concrete material:
The unit of measurement shall be the metre of saw-cut. The length in each depth range shall be measured and paid separately.
The quantities shall be measured from the authorised length of saw-cut, and the depth specified or instructed by the Engineer.
The tendered rates shall include full compensation for saw-cutting the material.
Where asphalt and the underlying layer(s) are both to be saw-cut and the asphalt is less than 50 mm thick, separate measurement and payment
shall not be made for the asphalt saw-cutting in item C4.3.4.1. The asphalt thickness shall then be added to the thickness of the material in items
C4.3.4.2 and/or C4.3.4.3 as applicable.
C4.3.5 Providing the milling machine on the site
C4.3.5.1 Small milling machine with a cutting width of 1,2 m or smaller number (No)
C4.3.5.2 Large milling machine with a cutting width exceeding 1,2 m number (No)
The unit of measurement shall be the number of milling machines provided on the site, or the number of times a milling machine is brought onto
the site where it had to be removed temporarily with prior approval. De-establishment and subsequent re-establishment shall also only be
measured if undertaken with prior approval.
The tendered rates shall include full compensation for establishment and for de-establishment of the milling machine.
Payment for returning the machine to the site after removal shall be made only where the removal was in accordance with the Contractor’s
approved programme of work and not for any other reason. Payment shall not be made for replacing any defective plant.
Payment shall also not be made for moving the milling machine around on the site.
C4.3.6 Milling and removal of existing asphalt layers with an average milling depth
(Contractor takes ownership)
C4.3.6.1 Not exceeding 50 mm cubic metre (m3)
C4.3.6.2 Exceeding 50 mm but not exceeding 100 mm cubic metre (m3)
C4.3.6.3 Exceeding 100 mm cubic metre (m3)

C4.3.7 Milling and removal of existing asphalt layers with an average milling depth
(Employer takes ownership)
C4.3.7.1 Not exceeding 50 mm cubic metre (m3)
C4.3.7.2 Exceeding 50 mm but not exceeding 100 mm cubic metre (m3)
C4.3.7.3 Exceeding 100 mm cubic metre (m3)
The unit of measurement for items C4.3.6 and C4.3.7 shall be the cubic metre of material milled from the existing pavement.
The quantities shall be computed in accordance with the authorised dimensions of the excavation.
When instructed, split milling and removal of the different existing asphalt layers shall be measured individually.
The tendered rates for item C4.3.6 shall include full compensation for demarcating the excavation, for milling (excavating) the material, for loading
and hauling to a site identified by the Contractor, and for spoil or re-use by the Contractor. All haul costs shall be included in the tendered rates of
item C4.3.6.
The tendered rates for item C4.3.7 shall include full compensation for demarcating the excavation, for milling, loading, hauling and
off-loading the material at a site designated by the Employer. Haul shall be measured from the point where the material is loaded to where it is
off-loaded.
Trial milling shall be measured and paid for under items C4.3.6 or C4.3.7, and no separate payment shall be made for it.
C4.3.8 Excavating material by milling
C4.3.8.1 Crushed stone material cubic metre (m3)
C4.3.8.2 Cemented material cubic metre (m3)
C4.3.8.3 Natural gravel material cubic metre (m3)
The unit of measurement shall be the cubic metre of milled material.

The quantities shall be measured in place on the existing road before the excavation commences.
The tendered rates shall include full compensation for milling out and loading the material.
Trial milling shall be measured and paid for under item C4.3.8, and no separate payment shall be made for it.
C4.3.9 Excavating material by using conventional road construction equipment
C4.3.9.1 Asphalt material cubic metre (m3)
C4.3.9.2 Crushed stone and macadam materials cubic metre (m3)
C4.3.9.4 Natural gravel and sand materials cubic metre (m3)
C4.3.9.5 Coarse fill and rock fill cubic metre (m3)
The unit of measurement shall be the cubic metre of excavated material, by using conventional road building equipment.
The quantities shall be measured in place on the existing road before the excavation commenced.
The tendered rates shall include full compensation for excavating and loading the material.
The tendered rate for cemented material shall include for ripping or pulverising the material prior to excavating.
C4.3.10 Excavating material by using labour enhanced methods of construction
C4.3.10.2 Crushed stone and macadam materials cubic metre (m3)
C4.3.10.4 Natural gravel and sand materials cubic metre (m3)
The unit of measurement shall be the cubic metre of excavated material, by using labour enhanced methods of construction.

The quantities shall be measured in place on the existing road before the excavation commenced.
The tendered rates shall include full compensation for excavating and loading the material.
C4.3.11 Breaking down a stabilised layer by using conventional road construction equipment cubic metre (m3)
The unit of measurement shall be the cubic metre of stabilised material that is broken down, by using conventional road building equipment.
The quantities shall be measured in place on the existing road, from thickness measurements determent by drilling cores or in trial pits.
The tendered rate shall include full compensation for all equipment, labour and supervision to break the stabilised layer. No distinction shall be
made between ripping the material with a grader, or pulverising the material with a recycler or rotary machine.
Measurement and payment in this item shall only be made when the existing material is used in a side-cut to new pavement layer operation. For
excavating the existing material and then remove it to stockpile or to spoil, measurement of item C4.3.9 shall apply that includes the breaking
down by ripping or pulverising.
C4.3.12 Removing of existing concrete material within the following average depth ranges
C4.3.12.1 The break-up method:
(a) Not exceeding 150 mm cubic metre (m3)
(b) Exceeding 150 mm but not exceeding 250 mm cubic metre (m3)
C4.3.12.2 The break-up method using labour enhanced methods of construction:
C4.3.12.3 The lift-out method:
The unit of measurement shall be the cubic metre of concrete removed.

The quantity shall be measured in place on the road or in the sidewalk before the concrete is broken up or lifted.
The tendered rates shall include full compensation for drilling of cores, and for removing and loading the concrete.
C4.3.13 Lifting of existing paving blocks (specify the type or size and thickness)
C4.3.13.1 Using construction equipment square metre (m²)
C4.3.13.2 Using labour enhanced methods of construction square metre (m²)
The unit of measurement shall be the area of paving blocks lifted.

The quantities shall be measured in place on the road or in the sidewalk before the blocks are lifted.
The tendered rates shall include full compensation for lifting the paving blocks and for removing the bedding sand.
C4.3.14 Removing of existing road edging and services structures
C4.3.14.1 Removing of existing road edging using construction equipment:
(a) Kerbing and edge beams:
(i) In situ concrete kerbing and edge beams cubic metre (m3)
(ii) Precast concrete kerbing (specify type or figure number) metre (m)
(iii) Precast concrete kerbing (specify type or figure number) and situ concrete channel metre (m)
(specify dimensions)

(b) Kerb inlets number (No)
(c) Grid inlets number (No)
(d) Etc., for other services structures number (No)
C4.3.14.2 Removing of existing road edging using labour enhanced methods of construction:
(a) Kerbing and edge beams:
(i) In situ concrete kerbing and edge beams cubic metre (m3)
(ii) Precast concrete kerbing (specify type or figure number) metre (m)
(iii) Precast concrete kerbing (specify type or figure number) and situ concrete channel metre (m)
(specify dimensions)
(b) Kerb inlets number (No)
(c) Grid inlets number (No)
(d) Etc., for other services structures number (No)
The unit of measurement for items C4.3.14.1(a)(i) and C4.3.14.2(a)(i) shall be the cubic metre of concrete removed.
The unit of measurement for items C4.3.13.1(a)(ii) and (iii) and C4.3.14.2(a)(ii) and (iii) shall be the metre of precast kerbing removed. For items
C4.3.14.1(a)(iii) and C4.3.14.2(a)(iii) the length of in situ concrete channel shall not be measured separately.
The unit of measurement for items C4.3.14.1(b) and (c) and C4.3.14.2(b), (c) and (d) shall be the number of inlets.
The quantities shall be measured in place on the road before the items are removed.
The tendered rates shall include full compensation for excavation, breaking down and removing the edging.
C4.3.15 Stockpiling of road layer materials
C4.3.15.2 Crushed stone material cubic metre (m3)
C4.3.15.4 Natural gravel material cubic metre (m3)
C4.3.15.5 Concrete pavements cubic metre (m3)
The unit of measurement shall be the cubic metre of material stockpiled.

The quantities shall be measured in place on the road before excavation commenced.
The tendered rates shall include full compensation for hauling the first 1,0 km of milled or excavated material to the stockpile, and for spreading
and maintaining the material in the stockpile.
Haul shall be measured starting 1,0 km from the centre point where the material is loaded to where it is off-loaded.
C4.3.16 Stacking paving blocks and road edging
C4.3.16.1 Paving blocks (specify type or size and thickness) number (No)
C4.3.16.2 Precast concrete kerbing (specify type or figure number and length of sections) number (No)
C4.3.16.3 Precast kerb inlets number (No)
C4.3.16.4 Precast manholes number (No)
The unit of measurement shall be the number of units that are neatly stacked at the approved stockpile site.
The quantities shall be measured in the stockpile (stack).
The tendered rates shall include full compensation for cleaning the paving blocks or road edging items, for loading and hauling to the stockpile
(stacking) site or to a position as indicated by the land or property owner, for off-loading and stacking.

C4.3.17 Excavate non-compliant or excess pavement layer material to spoil in sites

designated by the Employer, material consisting of
C4.3.17.2 Crushed stone, macadam, gravel and sand material cubic metre (m3)
C4.3.17.4 Concrete material cubic metre (m3)
The unit of measurement shall be the cubic metre of material spoiled.

The quantity shall be measured in place on the road before excavation commenced. Where this method of quantification is not feasible or where
the quality of material is only identified after it has been excavated, the Engineer may approve that the quantity be taken as equal to 70 % of the
loose volume of the material in the haul vehicles be used to transport asphalt, crushed stone, macadam, gravel, sand and cemented materials,
and in the case of concrete materials to 50 % of the loose volume of material in the haul vehicles.
The tendered rates shall include full compensation for breaking down the material, excavating, and for disposing the material, including shaping
and levelling-off any heaps of spoil material.
C4.3.18 Excavate non-compliant or excess pavement layer material to spoil in sites

designated by the Contractor, material consisting of
C4.3.18.2 Crushed stone, macadam, gravel and sand material cubic metre (m3)
C4.3.18.4 Concrete material cubic metre (m3)

The quantity shall be measured in place on the road before excavation commenced. Where this method of quantification is not feasible or where
the quality of material is only identified after it has been excavated, the Engineer may approve that the quantity be taken as equal to 70 % of the
loose volume of the material in the haul vehicles.
The tendered rates shall include full compensation for negotiations with the land owner or legal occupant of the property or of the spoil site, for
breaking down the various materials, excavating, loading and hauling the material to the spoil sites irrespective of the haul distance, for off-loading
and disposing the material, and for finishing the spoil site and obtaining the approval of the property or spoil site owner, if applicable.
The tendered rate shall also include the cost of spoiling at a municipal site, if applicable.
C4.3.19 Spoiling of paving blocks and road edging in spoil sites designated by the Employer
C4.3.19.1 Paving blocks cubic meter (m³)
C4.3.19.2 Precast and in situ concrete kerbing, edge beams and channels at precast kerbing cubic metre (m3)
C4.3.19.3 Kerb and grid inlets, and other services structures number (No)

The quantities shall be taken as equal to 70 % of the loose volume in the haul vehicles.
The tendered rates shall include full compensation for loading the materials, and for disposing the materials. The tendered rates shall also include
the cost of spoiling at a municipal site, if applicable.

C4.3.20 Spoiling of paving blocks and road edging in spoil sites designated by the Contractor
C4.3.20.1 Paving blocks cubic meter (m³)
C4.3.20.2 Precast and in situ concrete kerbing, edge beams and channels at precast kerbing cubic metre (m3)
C4.3.20.3 Kerb and grid inlets, and other services structures number (No)

The quantities shall be taken as equal to 70 % of the loose volume in the haul vehicles. The tendered rates shall include full compensation for
loading the materials, for hauling to the spoil site irrespective of the haul distance, and for off-loading and disposing the materials.
The tendered rates shall also include the cost of spoiling at a municipal site, if applicable.

D4.3 EXISTING ROAD MATERIALS
CONTENTS
D4.3.1 SCOPE
D4.3.2 GENERAL

4.4 COMMERCIAL MATERIALS
CONTENTS
A4.4.1 SCOPE
A4.4.2 DEFINITIONS
A4.4.3 GENERAL
A4.4.5 MATERIALS
A4.4.8 WORKMANSHIP

A4.4 COMMERCIAL MATERIALS

A4.4.1 SCOPE
This Section covers:
• The provision of natural or crushed materials for a specific road construction project or projects that are procured from commercial and other
private sources. It includes information on the requirements for providing the commercial materials for earthworks and road pavement layers
as an alternative to sourcing these materials from borrow pits, from quarries, from cuttings, box cuts and designated excavations or from
existing roads.
• The provision of commercial agents and additives that are added or worked into the available materials or road pavement layers to enhance,
improve or alter their properties so that the materials then comply with the specified quality and strength requirements. Commercial agents
and additives comprise traditional stabilising agents, non-traditional stabilising or soil treatment agents, and dust palliatives. The selection
(design) process to determine the optimum quantity of cementitious and bituminous stabilising agents is also covered in this Section.
SANS test methods published by Standards South Africa (a subdivision of the SABS) are listed in Chapter 20. The Sabita Guideline TG2 can
also be consulted for tests on bitumen stabilised materials.
A4.4.2 DEFINITIONS
The relevant definitions in Chapter 1 and Clause A4.1.2 shall also be applicable to this Section. Additional definitions for this Section are listed
below.
Commercial materials - are natural gravel, sand or crushed rock materials:
• Sourced from commercial suppliers. These materials are sold by commercial suppliers and are generally crushed materials acquired
from quarry operations or from stockpiles of non-ore containing material excavated during mining operations and shall already comply
with the gradation and other material requirements, or
• Sourced from private or other non-commercial suppliers identified by the Employer or the Contractor, or material from the Employer’s
or Contractor’s own sources. These materials are usually natural materials available in excavations or stockpiles, and the primary
objective for excavating the material is/was not for road construction purposes. It is distinguished from material sourced from borrow
pits and quarries in Section 4.1, in that the excavation or sourcing does not require a mining right or a mining permit in terms of South
African legislation, although other legislative approvals may be required. Commercial materials from private or other non-commercial
suppliers or from the Employer’s own sources may require removal or breaking down of oversize material, screening, crushing or
crushing and screening.
Dust palliatives - are products applied to the surface of a wearing course of an unsealed road or worked into the layer to reduce the dust and
loss of fines.

Non-traditional stabilising or soil treatment agents - non-traditional stabilisation or soil treatment agents can be:
• Sulfonated petroleum products (SPPs), also known as ionic soil stabilisers.
• Polymers, essentially plastic materials derived from acrylic polymers and commonly used as household glues.
• Nano-technology products that utilise processes at the molecular level within bitumen to improve the material properties.
Non-traditional stabilising or soil treatment agents are sometimes also referred to as proprietary stabilising agents.
Stabilisation - is the treatment of natural or crushed material to enhance the strength (load bearing capacity) and stiffness, and/or to make the
material more water resistant to improve the durability. Marginal non-compliant material can also be made compliant for use after stabilisation.
Stabilisation of material may take place by means of mechanical modification, also referred to as granular stabilisation (for example material
blending), chemical (for example mainly modification or modification and cementation), electrical (for example ion exchange), or material
improvement (for example using bitumen emulsion or foamed bitumen).
Traditional stabilising agents - these are agents that have generally been used through the years to stabilise materials, and are classified as:
• Cementitious stabilising agents (cement and lime}, also referred to as stabilisers.
• Bituminous stabilising agents (added as an emulsion or in a foamed state).
A4.4.3 GENERAL
A4.4.3.1 Employer identified commercial materials
a) Materials from commercial suppliers
The Employer may identify and include test results of compliant materials from commercial suppliers in the Contract Documentation. However,
the Contractor shall still be responsible for sourcing the material and for ensuring the sufficiency in quantity and quality of the material intended
for use in the contract.
The Employer will usually not conclude any arrangements with these commercial suppliers, and the Contractor shall enter into negotiations with
them and conclude contracts for the price, payments, rate of supply and the like.
Once the Contractor has chosen one or more of the commercial suppliers identified by the Employer, further dealings with the supplier and
procuring the material shall be undertaken by the Contractor.
b) Materials from private or non-commercial suppliers
The sources and results of any material testing of materials from private or non-commercial suppliers that have been identified by the Employer,
will be included in the Contract Documentation. This information is indicative as to the sufficiency in quality and quantity of the material.
The Contract Documentation shall also specify the arrangements made with the suppliers and specifically those that the Contractor must comply
with, and any further negotiations that the Contractor shall conclude.
c) Materials from the Employer’s own sources
The material is free issued to the Contractor, unless otherwise stated in the Contract Documentation when any conditions of the Employer shall
then also be specified.
The results of any material testing will also be included in the Contract Documentation.
A4.4.3.2 Contractor identified suppliers or sources

When no commercial sources are identified by the Employer in the Contract Documentation or if so instructed, the Contractor shall identify
compliant material sources. The Contractor can also identify compliant commercial or private / non-commercial material sources, or material from
the Contractor’s own sources, other than those identified by the Employer for utilisation in the works as an alternative material source.
Proof of the approvals and authorisation by the appropriate authorities for the commercial or private / non-commercial sources identified by the
Contractor, as applicable, shall be provided by the Contractor.
The Contractor shall be responsible for all contractual and legal matters pertaining to ordering, loading, delivering and paying for materials obtained
from the Contractor identified commercial or private / non-commercial suppliers.
The Contractor shall also ensure compliance by the suppliers of commercial or private / non-commercial materials that the necessary negotiations
have been concluded with other interested and affected parties, as well as any land acquisitions, royalty payments and any special conditions
imposed by these parties. If required, the Contractor shall submit proof or confirmation of all approvals and agreements before delivering any
commercial materials to the site.
When the Contractor is responsible to procure commercial materials, test results of the natural material as prescribed shall be submitted to the
Engineer to assess. The Engineer shall then declare the material fit for use before it can be sourced.
When the materials are proposed by the Contractor as an alternative material source to those identified by the Employer, the Contractor shall
arrange for the required testing to proof the compliance of the natural material properties and for the design of the stabilised material as applicable
at no cost to the Employer. The type and amount of stabiliser required shall be determined in accordance with the testing protocol in Clause
A4.4.7. The test results, along with a proposal regarding the stabiliser type and stabiliser content, and the financial benefit for the Employer shall
be submitted for review to the Engineer and acceptance before the material is sourced.

Should the Contractor wish to use, or to propose alternative commercial materials to those available from the designated borrow pits or quarries
provided under Section 4.1, then sufficient laboratory test results must be provided to confirm that the Contractor’s proposed commercial materials
comply with the specified material properties.

The dust palliative shall be subject to a performance based system. Particulars of the system are given in Part D of this Section.
A4.4.5 MATERIALS
A4.4.5.1 Earthworks and pavement layer materials
The specifications for a pioneer layer, fill material and crushed stone for earthworks given in Clause A4.1.5 shall also apply to commercial materials.
These material specifications are the required specifications for the commercial material finally processed and constructed on the road.
Test results from representative samples recently processed shall be submitted for review by the Engineer. The Engineer shall declare the
sourced or produced material fit for use before construction on the road may commence.
When specified in the Contract Documentation, material procured from commercial suppliers shall be stockpiled separately at the supplier when
it cannot be used immediately after producing. The Contract Documentation may then also specify that the stockpile be fenced and sign posted
as belonging to the Employer.
A4.4.5.2 Traditional cementitious stabilising agents

The traditional cementitious stabilising agents for chemical stabilisation shall be either one or more of the agents listed hereunder.
a) Cement
Cement, also known as common cement, shall comply with the requirements of SANS 50197. Only extended common cement with a strength
class of 32.5N shall be used.
The following common cements shall not be used for stabilisation:
• CEM I due to rapid setting.
• CEM III/B, III/C and V/B due to a low clinker content.
• High early strength cements, affixed by the symbol “R”, except where early strength is required for trafficking and compaction is
completed within the field working time established during the stabilisation design.
Masonry cement, even if it complies with the requirements of SANS 50413, shall also not be used for stabilisation.
Proprietary cement blends that do not necessarily comply with SANS 50197 will be considered by the Engineer as stabilising agent, provided it
has a proven record of being used and the requirements in Table A4.4.5-2 are complied with.
b) Lime
Road lime for the treatment of road materials can be calcium lime, magnesium lime or dolomitic lime. Lime shall comply with the requirements of
SANS 824. All lime used for road stabilisation shall be slaked lime, also known as hydrated lime. Unslaked lime, also known as quicklime, and
agricultural lime shall not be used.
c) Blending of cement with GGBS or PFA
The practise of site blending of cement with ground granulated blast furnace slag (GGBS) or pulverised fly ash (PFA) is not necessary, and has
been eliminated by the availability of the extended cements classified by SANS 50197.
A4.4.5.3 Traditional bituminous stabilising agents

a) Bitumen
Bitumen used as a stabilisation agent for bitumen stabilised material (BSM) shall be one of the following products and shall comply with the
applicable standards:
• Penetration grade bitumen: SANS 4001-BT1 (for BSM – foam).
• Anionic road emulsion: SANS 4001-BT3 (for BSM – emulsion).
• Cationic road emulsion: SANS 4001-BT4 (for BSM – emulsion).
(i) Bitumen emulsion
Bitumen emulsion shall usually be slow set, stable grade anionic emulsion.
Cationic bitumen emulsion is generally more compatible with acidic aggregates having high silica content and low alkali content such
as quartzite, granite, sandstone, rhyolite, syenite and felsite.
(ii) Foamed bitumen
Foamed bitumen shall be produced by injecting a limited amount of water (typically between 2 % and 4 % by mass of the bitumen)
into a 70/100 penetration-grade bitumen, which has been pre-heated to a temperature of 170 °C to 180 °C. The minimum foaming
characteristics (in terms of expansion ratio and half-life) shall be as specified in Table A4.4.5-1.
Table A4.4.5-1: Foaming characteristic limits (minimum values)
Aggregate temperature (°C) 15 – 25 > 25
Bitumen temperature (°C) 160 - 190
Expansion Ratio (times) 10 8
Half-Life, τ1/2 (seconds) 8 6

b) Active fillers
Fillers, also referred to as active fillers, such as hydrated lime or cement are introduced into the material requiring to be bitumen stabilised
depending on the outcome of the laboratory mix design.
Cement, preferably CEM II 32.5N, and hydrated lime shall comply with the requirements of Clauses A4.4.5.2a) and A4.4.5.2b) above respectively.
A4.4.5.4 Non-traditional stabilising or soil treatment agents

The use of non-traditional stabilising or soil treatment agents may be specified in the Contract Documentation. Details of the product, its method
and rate of application, construction method statement and any applicable curing measures, measurement and payment shall then be provided.
Should the Contractor propose the use of a non-traditional stabilising or soil treatment agent, either as an alternative to the specified product or
to enhance the properties of any material, it shall only be considered when the following information is submitted for review by the Engineer:
• Details of the type of agent and basis material,
• A cost comparison that shows it to be economically viable compared to traditional stabilising or soil treatment agents,
• Test results show that the non-traditional agent is effective in achieving the specified material properties for the applicable layer,
• The product is accredited by a recognised body, such as Agrément South Africa, or project details of previous successful use of the
product with the specific project test results, references and contact details are submitted, and
• The application specifications from the supplier, a method statement describing the application and processing of the stabiliser, and
an equipment list to apply the agent and for the construction of the layer.
A4.4.5.5 Chemically stabilised materials

The material requirements for the different classes of chemically stabilised materials to achieve cementation are given in Table A4.4.5-2.
Table A4.4.5-2: Requirements for cemented chemically stabilised materials
Classification C2 C3 C4
At least G4A At least G5B At least G6

Type of material before stabilisation
quality quality quality
Maximum particle size 50 mm Base 50 mm, Subbase 63 mm
Basic crystalline material: NP

PI after stabilisation Non-plastic
Other materials: 6
Min 3,0 1,5 0,75

UCS (Unconfined Compression
Strength) (MPa) at 100 % of MDD(1)
Max 5,0 3.0
Min 300 250 200

ITS (Indirect Tensile Strength) (kPa)
at 100 % of MDD
Max 600 500(2) 450(2) (350)(3)
WDD (Wet/Dry Durability) (mass loss maximum) 10 % 20 % 30 %

Notes:
(1)
It is more important that the ITS requirements be met than the UCS requirement, as the ITS affects both the structural behaviour of the layer and
limits the potential of the material to degrade should the durability decreases in time.
(2)
Maximum ITS values for a subbase can be exceeded when subbase under a sound G1 crushed stone base layer or block paving.
(3)
ITS in brackets applies for a stabilised base layer.
The UCS and ITS requirements in Table A4.4.5-2 are determined at the standard 7-day curing, and not at the 24-hour rapid or accelerated curing
testing. The 7-day cured strengths shall always be taken as the reference requirements, as the rapid curing may give a higher strength. Should
rapid curing be done during the construction, both tests shall be done in parallel and a calibration factor derived for that material with that specific
stabiliser. The rapid testing can then be used for acceptance control provided that regular calibration checks are made against the 7-day cured
strengths to ensure that nothing has changed significantly. When significant variations are found in the relationship between the results of the
two types of test, then all further test samples that are rapid cured shall have duplicate samples that are tested by the standard full 7-day
acceptance test until a reliable, stable calibration factor has been re-established.

A4.4.5.6 Bitumen stabilised materials
The material requirements for the different classes of bitumen stabilised material (BSM) are given in Table A4.4.5-3.
Table A4.4.5-3: Requirements for BSMs
BSM Classification
Specimen size, compaction effort
Test(1)
and curing
BSM1 BSM2
Type of material before stabilisation At least G4B quality At least G5B quality
Grading, P0,075, PI and DMI for BSM-emulsion and BSM-foam Refer the Sabita Guideline TG2
ITSDRY (Indirect Tensile > 225 > 175

Strength) (kPa) 152 mm dia x 95 mm high
vibratory hammer or MDD compaction
ITSWET (Indirect Tensile cured to constant mass(2) > 125 > 100
Strength) (kPa)
Friction angle (°) > 40 (38) > 38 (35)

Shear parameters(3)
150 mm dia x 300 mm high

Cohesion (kPa) vibratory hammer compaction > 250 (265) > 200 (225)
cured at equilibrium moisture content(4)
Retained cohesion (%) > 75 (75) > 65 (75)
Notes:
(1)
All tests are carried out on specimens conditioned at 25 °C.
(2)
Specimens cured to constant mass at 40 °C. ITS values determined using constant displacement loading.
(3)
Requirements in brackets when the reclaimed asphalt in the material exceeds 50 %.
(4)
Specimens conditioned to 40 °C for 8 hrs before sealing in a bag and curing at 40 °C for 48 hours.
The selection of the bituminous stabilising agent is covered in Clause A4.4.7.1.
A4.4.5.7 Treated or modified materials

The material properties after treatment or modification shall comply with the relevant requirements specified in Section A4.1,
Tables A4.1.5-3, A4.1.5-4 or A4.1.5-5.

It is the Contractor’s responsibility to ensure that the commercial materials including the procuring, loading, hauling, and/or further stockpiling if
applicable, shall comply with the material specifications.
Any approval or consent given previously for the use of any commercial material may be cancelled, if the material quality has altered so that it
does not comply with the specifications anymore.

For materials obtained from commercial suppliers, an equipment list does not have to be submitted.
For materials sourced from private or non-commercial suppliers or from the Contractor’s own resources, the requirements in Clause A1.2.6 of
Chapter 1 shall be applicable for the construction equipment.

A4.4.7.1 Selection (design) of the stabilising agent content
a) Purpose of the selection process
The purpose of selecting the stabilisation content is to find the optimum combination of gravel or crushed material and stabilising agent that will
provide the required strength and durability to ensure adequate structural capacity of the layer but not excessive for the design life of the road.
This requires that the correct type and quantity of stabilising agent are determined.
b) Sampling of materials
For determining the positions of sampling and trial pits and during the taking of samples, it shall always be remembered that material properties
can vary. Crushed aggregate, and more so gravels which are partly weathered, have properties that can vary considerably as a result of the
effect of chemical reactions (hydration, hydrolysis and so forth), physical processes (leaching, saturation and so forth) and the effect of the
environment (depth, water flows, temperatures and so forth). Adequate sampling shall always be carried out to ensure that representative test
results are obtained. Samples shall also be taken from the point of availability of the material earmarked for stabilisation (generally in stockpile).

c) Cementitious stabilising agent for chemical stabilisation
The Engineer, in consultation with the Contractor, will carry out the process to select the cementitious stabilising agent in an agreed to laboratory.
The Contractor shall provide the laboratory with an adequate quantity of the natural material and stabilising agent for the laboratory to use in the
testing procedures. The stabilisation design testing may take up to 8 weeks to conclude. The Contractor shall identify the material for stabilisation
timeously to prevent delays to the contract.
The cementitious stabilising agent selection process for stabilisation shall be undertaken in a four-step sequence.
Step 1: Determine the compliance of the natural material.
The natural or untreated material shall be tested for compliance. Refer Table A4.4.5-2 in this Section and Tables A4.1.5-3, A4.1.5-4 and
A4.1.5-5 in Section A4.1. The material may have to be processed by crushing, screening or crushing and screening, blended with other materials
or pre-treated with lime or another stabilising agent if required, to meet the specifications of the material before stabilisation testing commences.
The material shall also be tested for deleterious minerals, especially for sulfates, for compliance with the requirements in Section 4.1
Clause A4.1.5.17.
Sugar has also deleterious effects on cement that may affect stabilisation in sugarcane farming areas. The presence of sugar in material in these
areas must be tested in accordance with SANS 5833.
Step 2: Determine the Initial Consumption of Stabiliser (ICS) of the material.
The pH shall be tested of samples prepared at varying stabiliser contents. The stabiliser content in percentage at which the pH reading does not
increase by more than 0,1 % compared to the next reading, shall be taken as the ICS of the material.
Step 3: Determine the compliance of the stabilised material.
Samples of the material and stabilising agent shall then be prepared at stabiliser contents of 1,0 %; 1,5 %; 2,0 % and 2,5 % more than the ICS
percentage identified in Step 2. The PI, UCS and ITS of all samples shall be tested at 7-day curing and evaluated against the requirements in
Table A4.4.5-2. Samples cured at 24-hour rapid curing shall also be prepared and tested the same time for comparison with the 7-day curing
results, should the results of the rapid curing be used for the construction quality control.
If it is not possible to fully comply with both the UCS and ITS specified requirements, then compliance with the ITS requirement takes precedence.
The selected stabilising agent and content, increased to represent the construction method, will then be chosen that meet the requirements for PI
and ITS in Table A4.4.5-2.
When required by the Engineer, the addition of more stabilising agent to allow for variations in material properties and stabiliser distribution shall
be assessed during the construction of the trial section specified in Chapter 5.
Step 4: Determine the durability of the stabilised material, the effect of the test curing period on the ITS, and the field working time.
The Engineer shall indicate the stabiliser content(s) for the tests below, but it shall generally be carried out at the content chosen in Step 3 and at
a stabiliser content of 0,5 % higher.
(i) Durability of the stabilised briquettes
For durability the wet/dry brushing test shall be done. Should the wet/dry durability (WDD) requirement in Table A4.4.5-2 be met, the Engineer
shall then confirm the stabilising agent and the application rate. Should the wet/dry durability requirement not be met, the test shall be repeated
with higher contents of stabilising agent until the durability specification is met, or other types of stabilising agent shall be considered and the
design steps repeated.
Stabilisation on the road may be permitted by the Engineer before the results of the wet/dry durability test are available, but only where historical
results of the durability tests on material from the same source have complied with the specification.
(ii) ITS correlation between 7-day and 24 hr curing times
Parallel testing shall be carried out to establish for quality assurance testing the correlation between the ITS values at 7-day curing at the
temperature of the standard test, and of the rapid curing test of 24 hours at elevated temperature, on material with the same stabiliser content.
(iii) Field working time
This test procedure for the field working time gives an indication of the maximum time for completion of the stabilised layer after commencement
of the addition of the stabilising agent to the material. The working time shall be assessed by testing the ITS at rapid curing at increasing standing
periods after the stabilising agent is mixed with the material. The field working time limit is then where the specified ITS requirement can still be
achieved. The specified working time for construction stabilisation shall not exceed the construction time limitations specified in Section 5.4 of
Chapter 5.
d) Bituminous stabilising agent for material improvement
The Engineer, in consultation with the Contractor, will carry out the process to select the bituminous stabilising agent in an agreed to laboratory.
The requirements for the various test results hereunder are specified in Table A4.4.5-3. The Contractor shall provide the laboratory with a sufficient
quantity of the bituminous stabilising agent and active fillers for use in the various testing procedures.
The stabilising agent selection process of BSMs shall be undertaken in a three-step sequence as below. (Note: a more extensive explanation and
description is given in the Sabita Guideline TG2).
Step 1: Determine the compliance of the natural material.
The selection process starts by testing whether the natural material to be treated is compliant for treating with bitumen and, if not, to ascertain the
producing of the material by crushing, screening or crushing and screening, and if pre-treatment is required, with a cementitious stabilising agent
or blending with other materials to make it compliant. For the material requirements refer Table A4.4.5-3 in this Section and Tables A4.1.5-4 and
A4.1.5-5 in Section A4.1.
Step 2: Determine the effect of active filler and the optimal binder content.
ITS tests are carried out to determine the effect of adding an active filler in conjunction with the bituminous stabilising agent. Three samples are
normally tested, all with the same application of bituminous stabilising agent. Following the relevant test procedure, no active filler is added to the

first sample, 1 % (by mass) cement is added to the second sample and 1 % (by mass) hydrated lime is added to the third sample. (Additional
samples may be treated with other active fillers or a greater mass of filler if required.) Six ITS specimens are manufactured from each of the three
(or more) treated samples. After curing, half the ITS specimens are soaked in water for 24 hours before testing to determine the ITSWET values.
The ITSDRY values are obtained from the unsoaked ITS specimens.
The active filler in the mix that achieves the highest ITSWET value is selected as the preferred active filler and is applied to the mixes used to
manufacture specimens for all further tests.
(Note. When there is a significant increase in the ITSDRY value of specimens treated with and without active filler, the ITS test procedure is
repeated with a reduced application rate of 0,75 % active filler.)
Similar to the procedure to select the optimal filler content, ITS tests are carried out to determine the effect of adding different amounts of
bituminous stabilising agent to samples all treated with the same amount of active filler. The ITS DRY and ITSWET values achieved are plotted
against the respective amounts of stabilising agent on a graph, and the amount of agent that yields the ITS values specified for the required BSM
classification is selected as the optimum.
Step 3: Evaluate the shear properties.
A large sample is prepared by adding active filler and bituminous stabilising agent at the application rates determined in Steps 1 and 2. Ten
150 mm diameter x 300 mm high specimens are manufactured and cured. Monotonic triaxial tests are then carried out on eight of the specimens
(2 each at 4 different confining pressures) to determine the shear properties (the internal friction angle and cohesion) as well as the retained
cohesion (determined from tests on the remaining two samples after soaking in water for 24 hours).
A4.4.7.2 Storage of stabilising agents on site

a) Cement provided in pockets
Cement delivered in pockets can be kept at the road on pallets or on a raised platform for no longer than two weeks. The pockets shall always
be protected from the ingress of any moisture with a waterproof tarpaulin or plastic cover not less than 1,0 mm thick.
For longer storage periods, the cement bags shall be stored in a shed. The requirements for the shed and for storing are:
• Storage sheds shall be watertight and of solid construction.
• The floor shall be waterproof and covered with plastic sheets not less than 1,0 mm thick.
• The pockets shall be stored on the delivery pallets, which must be stacked closely together (to reduce the circulation of air) and away
from any outside walls.
• Pockets shall be stored in such a way that older pockets are used first.
• Vertical stacking of loose pockets shall not exceed 12 pockets high.
• Doors and windows shall be kept shut.
The permitted shelf life of cement stored in a shed is 6 months inland and 3 months in coastal areas. Cement which has been properly stored in
an approved shed as specified above for longer than these periods, or at the road side for more than two weeks, shall not be used in the
stabilisation works.
b) Lime
Lime can be kept at the road for up to six months on pallets or on a raised platform. The pockets shall always be protected from the ingress of
any moisture with a waterproof tarpaulin or a plastic cover not less than 1,0 mm thick.
c) Bitumen
The maximum storage temperatures for penetration grade bitumens are given in Table A9.1.7.1 of Chapter 9. Binders stored in a heated condition
shall be kept in a container with a securely fitting lid and the circulatory system that is functioning properly. The container shall be provided with
a build-in thermometer. Binders which have been heated above the maximum allowed temperatures shall not be used and shall be removed from
the site.
Bitumen emulsion shall be stored at ambient temperature in storage tanks fitted with a circulating pump system, which will enable the stored
bitumen emulsion to be properly circulated in the static tank, especially when no bitumen emulsion has been drawn or added for a period of 2 to
3 consecutive days. The supplier shall be contacted for the maximum storage period.
d) Placing on the road
Pockets of stabilising agents shall only be placed immediately before the mixing and compaction operations are carried out, and after the gridlines
have been marked out on the surface to ensure the correct application rate. Where this is not practical and approved by the Engineer, then
pockets shall not be left on the road for longer than one day after placing the pockets prior to spreading the agent, as it may absorb moisture from
the underlying layer or be damaged during other construction activities.
When the pockets of stabilising agents are placed on the road during periods of wet weather and get wet before the agent is spread and mixed
into the layer, then the agent shall be removed to spoil and replaced with new dry agent at no cost to the Employer.
Where a pocket is broken on the road and mixing and compaction are not done within the specified time, the agent in the broken pocket shall be
removed to spoil and replaced with new dry agent at no cost to the Employer.
When the stabilising agent is delivered to site in bulk tankers then the agent may only be dispensed onto the road immediately before the mixing
and compaction operations are carried out.

A4.4.8 WORKMANSHIP
The Engineer and the Contractor shall determine and agree on the testing protocol and frequency of the applicable process control tests required
for the commercial materials, to ensure that the quality of the materials meets the specified requirements for the particular layer for which it will be
used.
The stabilised material and designs shall always be tested and evaluated by constructing and testing of a trial section. After the type and quantity
of stabiliser have been finalised, the Contractor shall further take full responsibility for compliance of the constructed stabilised layer with the
requirements.

B4.4 COMMERCIAL MATERIALS
CONTENTS
B4.4.1 SCOPE
B4.4.2 DEFINITIONS
B4.4.3 GENERAL
B4.4.5 MATERIALS

B4.4.8 WORKMANSHIP
B4.4.1 SCOPE
This Section covers the supply of materials for a specific road construction project or projects which are procured from commercial and other
private sources. It includes information on the requirements for providing commercial materials for earthworks and pavement layers as an
alternative to sourcing these materials from borrow pits, from quarries, from cuttings, box cuts and designated excavations or from existing roads
and that can be used for the construction of the road earthworks and pavement layers.
A relatively small proportion of activities as defined in Part A under the various sections are considered suitable for labour enhancement. Therefore,
B4.4.2 DEFINITIONS
B4.4.3 GENERAL

All specifications under this heading in the various sections of Part A, shall apply.
B4.4.5 MATERIALS


B4.4.8 WORKMANSHIP

C4.4 COMMERCIAL MATERIALS
(i) Preamble
Loading of the commercial materials at the source, hauling it to the road, and off-loading will not be measured and paid for separately.
For commercial materials from private or non-commercial suppliers identified by the Employer and that must still be excavated, produced and/or
stockpiled, the Employer may decide to have a cost breakdown of the individual activities such as excavation, crushing and so forth. The pricing
of item C4.4.1 will then not be applicable, and measurement and payment shall be made in accordance with the applicable items in Section C4.1.

Commercial materials identified by the Employer from commercial, private or other
C4.4.1
non-commercial suppliers (specify the source(s))
C4.4.1.1 Pavement layer material:
(a) Type G1 material cubic metre (m3)
(b) Type G2 material cubic metre (m3)
(c) – (l) Etc, for other Type G3 to G9 materials cubic metre (m3)
(m) Sand for the base and shoulder layers cubic metre (m3)
(n) Sand for a subbase layer cubic metre (m3)
(o) Sand for a selected layer cubic metre (m3)
(p) Natural or crushed gravel material for an unsealed shoulder layer cubic metre (m3)
(q) Natural or crushed gravel material for the wearing course of an unsealed road cubic metre (m3)
C4.4.1.2 Macadam material:
(a) Coarse aggregate cubic metre (m3)
(b) Fine aggregate cubic metre (m3)
C4.4.1.3 Drainage blanket layer material cubic metre (m3)
C4.4.1.4 Soil cement material (pre-blended by the supplier) cubic metre (m3)
C4.4.1.5 Fill material in the earthworks:
(a) Normal or coarse fill cubic metre (m3)
(b) Rock fill cubic metre (m3)
(c) Sand cubic metre (m3)
C4.4.1.6 Pioneer material cubic metre (m3)

The unit of measurement shall be the cubic metre of material.
The quantities for items C4.4.1.1 to C4.4.1.4 shall be measured in place in the compacted pavement layers and calculated from the authorised
dimensions of the layers.
The quantities for item C4.4.1.5 shall be measured in place, from the difference between levelled cross sections at 20 m maximum intervals taken
before and after the construction. The quantities shall not include excess material, overfill material or additional material placed for bulking
(settlement during compaction).

The quantity for item C4.4.1.6 shall be taken as equal to 50 % of the loose volume of the material in the haul vehicles.
The tendered rates shall include full compensation for negotiations to procure and furnish the commercial materials, for loading the material at the
source, hauling it to the road, and for off-loading. Temporary stockpiling of the material after procurement by the Contractor shall not be paid for.
The tendered rates for commercial materials from commercial suppliers shall also include full compensation for procuring the material. Additional
crushing, screening and stockpiling of commercial material acquired from commercial suppliers shall not be measured and paid for separately.
For commercial materials from private or non-commercial suppliers, separate measurement and payment shall be made for breaking down
oversize material, crushing, screening, and stockpiling as may be required and when specified in the Contract Documentation, or agreed to with
prior written approval by the Engineer. Measurement and payment shall then be made according to the applicable items in Section C4.1.
Procurement of the commercial material from the private or non-commercial suppliers by the Contractor, if specified in the Contract Documentation,
shall be measured and paid for separately under item C4.4.3.
The materials from different sources shall be measured and paid separately.
C4.4.2 Commercial materials identified by the Contractor from commercial, private or other
non-commercial suppliers
C4.4.2.1 Pavement layer material:
(a) Type G1 material cubic metre (m3)
(b) Type G2 material cubic metre (m3)
(c) – (l) Etc, for other Type G3 to G9 materials cubic metre (m3)
(m) Sand for the base and shoulder layers cubic metre (m3)
(n) Sand for a subbase layer cubic metre (m3)
(o) Sand for a selected layer cubic metre (m3)
(p) Natural or crushed gravel material for an unsealed shoulder layer cubic metre (m3)
(q) Natural or crushed gravel material for the wearing course of an unsealed road cubic metre (m3)
C4.4.2.2 Macadam material:
(a) Coarse aggregate cubic metre (m3)
(b) Fine aggregate cubic metre (m3)
C4.4.2.3 Drainage blanket layer material cubic metre (m3)
C4.4.2.4 Soil cement material (pre-blended by the supplier) cubic metre (m3)
C4.4.2.5 Fill material in the earthworks:
(a) Normal or coarse fill cubic metre (m3)
(b) Rock fill cubic metre (m3)
(c) Sand cubic metre (m3)
C4.4.2.6 Pioneer material cubic metre (m3)
The unit of measurement shall be the cubic metre of material.

The quantities for items C4.4.2.1 to C4.4.2.4 shall be measured in place in the compacted pavement layers and calculated from the authorised
dimensions of the layers.
The quantities for item C4.4.2.5 shall be measured in place, from the difference between levelled cross sections at 20 m maximum intervals taken
before and after the construction. The quantities shall not include excess material, overfill material or additional material placed for bulking
(settlement during compaction).
The quantity for item C4.4.2.6 shall be taken as equal to 50 % of the loose volume of the material in the haul vehicles.
The tendered rates shall include full compensation for negotiations, taking of samples and laboratory testing of the natural material to prove
compliance with the specified properties, procuring and furnishing the commercial materials, for loading the material at the source, hauling it to
the road, and for off-loading. Temporary stockpiling of the material after procurement by the Contractor shall not be paid for.
When the commercial materials are identified and proposed by the Contractor as an alternative material source to those identified by the Employer,
the tendered rates shall also include full compensation for taking of samples of the material, for laboratory testing of the natural material, and for
the stabilisation design and providing and applying stabilising agents should they be necessary to improve the properties of the natural material
to be compliant with the specifications.

No distinction shall be made for materials acquired from different sources.
C4.4.3 Cost to procure commercial materials identified by the Employer from private or
non-commercial sources
C4.4.3.1 Cost of procuring provisional sum
C4.4.4 Cementitious stabilising agents
C4.4.4.1 Cement ton (t)
C4.4.4.2 Road lime ton (t)
C4.4.4.3 Etc, for other agents ton (t)
The unit of measurement shall be the ton of stabilising agent.

The quantity of stabilising agent shall be determined in accordance with the authorised application rate. No over application or wastage shall be
measured for payment.
The tendered rates shall include full compensation for procuring, transporting and delivering the stabilising agent to the site. No distinction shall
be made between providing the stabilising agent in bulk or in pockets.
For providing the stabilising agent in pockets, the tendered rates shall also include full compensation for off-loading the pockets, for short term
and/or long term storage.
Placing, spreading and mixing in the stabilising agent(s) on the road shall be measured and paid for under the applicable items in
Chapter 5.
C4.4.5 Bituminous stabilising agents
C4.4.5.1 Penetration grade bitumen (specify grade) ton (t)
C4.4.5.2 Emulsion stable grade (specify type) ton (t)
The unit of measurement shall be the ton of bituminous stabilising agent.

The method of calculating the quantity shall be specified in the Contract Documentation or as agreed between the Engineer and the Contractor,
and shall be one of the following methods:
• Determined in accordance with the authorised application rate.
• Based on dipstick readings where the dipstick has been calibrated to the tanker, and the quantity measured at the applicable
temperature.
• Based on assized weighbridge tickets issued for each and every tanker-load of stabilising agent consumed in the stabilisation
process. The quantity thus measured shall not exceed the quantity calculated using the authorised application rate by more than
4 %.
The quantity shall include for a double treatment of stabilising agent over a nominal 150 mm overlap width along longitudinal joints.
The tendered rates shall include full compensation for procuring, transporting and delivering the bituminous stabilising agent to the site, for transfer
into storage tanks, storage and heating, for issuing the required assized weighbridge ticket showing the mass of the contents in the tanker if
applicable, for any re-heating required, for all wastage and for strict adherence to all safety measures required when handling warm bitumen
emulsion or hot bitumen. No distinction shall be made for supplying the stabilising agent in bulk or in drums.
Using and applying the bituminous stabilising agent in the road layers shall be measured and paid for under the applicable items in Chapter 5.
C4.4.6 Fillers for bituminous stabilisation (specify filler types separately) ton (t)
The unit of measurement shall be the ton of filler.

The quantity of filler shall be determined in accordance with the authorised application rate.
The tendered rate shall include full compensation for procuring and transporting the filler to the site, for off-loading and storing the filler.
Application of the filler and spreading on the road shall be measured and paid for under the applicable items in Chapter 5.

C4.4.7 Sampling and material testing by a commercial laboratory for the stabilisation designs
C4.4.7.1 Cost of sampling and material testing provisional sum

D4.4 COMMERCIAL MATERIALS
CONTENTS
D4.4.1 SCOPE
D4.4.2 GENERAL
D4.4.1 SCOPE
Dust palliatives shall be subject to the provision of a performance guarantee by the manufacturer and/or supplier of the dust palliative.
D4.4.2 GENERAL
The Employer shall identify the location and extent of the unsealed road for which a dust palliative is required.

D4.4.3.1 Information to be provided by the Employer
The Employer will provide the following basic information of the gravel wearing course material and requirements of the guarantee:
• Properties of the wearing course material,
• Expected volume and type of traffic on the road,
• Performance and other requirements for the palliative, whether for dust control, strengthening or both,
• Duration and format of the guarantee,
• Payment conditions of the guarantee, and
• Assessments and testing criteria for the treated material during the guarantee period.
D4.4.3.2 Information to be submitted by the Contractor
The Contractor shall submit the following information about the dust palliative:
• The type of dust palliative, whether it be one of the following types:
- A surfactant that is added to water in order to improve its ability to wet and penetrate the gravel wearing course,
- A non-bond forming palliative that is applied directly onto the wearing course surface and where there is no gluing of the surface,
or
- A bond forming or gluing palliative that bonds the dust particles and that is applied by mixing the palliative into the wearing course.
• The basis material of the palliative,
• Further application intervals during the guarantee period,
• Restriction on the use such as near watercourses or other environmentally sensitive areas,
• Construction and application methods,
• Construction equipment required to apply the palliative,

• Curing time and restrictions for opening the road,
• An inspection management system of the inspection frequency, items to be inspected and rating,
• A payment schedule of costs comprising the initial application and of further applications during the guarantee period,
• Expected condition of the wearing course at the assessment times and at the end of the guarantee period, and
• Project details of previous use of the dust palliative with project references and contact details.

Details must be provided in the Contract Documentation.


Details must be provided in the Contract Documentation when applicable.





4.5 ALTERNATIVE MATERIALS
CONTENTS
A4.5.1 SCOPE
A4.5.2 DEFINITIONS
A4.5.3 GENERAL
A4.5.5 MATERIALS
A4.5.8 WORKMANSHIP

A4.5 ALTERNATIVE MATERIALS

A4.5.1 SCOPE
This section covers the work requirements for sourcing alternative materials that can be used for the construction of road earthworks and road
pavement layers, and which are obtained from sources other than from borrow pits and quarries, or from cuttings, box cuts and designated
excavations, or from the existing road or from commercial sources.
A4.5.2 DEFINITIONS
The relevant definitions in Chapter 1 and Clause A4.1.2 shall also be applicable for this Section. Additional definitions for this Section are listed
below.
Alternative materials - include all recovered materials considered compliant for the construction of earthworks and pavement layers, with or
without additional processing, that are obtained from operations not necessarily related to road construction. Such operations include, but are not
limited to:
• Construction and demolition of structures.
• Industrial operations.
• Mining operations.
Geosynthetic materials built into the earthworks and road pavement layers are not defined as alternative materials.
Construction and demolition material - is produced in the process of construction, renovation, or demolition of structures. Structures include
buildings of all types (both residential and non-residential), as well as roads and bridges.
Components of construction and demolition material typically include concrete, bricks, mortar, asphalt, metals, floor tiles, roofing and ceiling
materials, dry walls, window materials, pipes, floor materials and other components. It may also contain some wood fragments, soil and rock
fragments. Construction and demolition material is also referred to as construction or building rubble.
Industrial operations material - material from industrial operations is typically a by-product produced by an industrial activity that includes any
surplus, unwanted or discarded material resulting from a manufacturing process at factories, mills, and so forth.
Mining operations material - material from mining operations generally consists of unprocessed surplus overburden material or non-ore bearing
material that was removed and stockpiled during the mining operation. It is generally not compliant for direct use in the road layers, and requires
removal of unwanted material, crushing and screening, and selection as applicable.
Hazardous material - contains organic or inorganic elements or compounds which may have a detrimental impact on health and the environment
owing to the inherent physical, chemical, toxicological, radioactive or carcinogenic characteristics of the material.

A4.5.3 GENERAL
The use of alternative materials may be specified in the Contract Documentation or be proposed by the Contractor. These alternative materials
could be used on their own or mixed (blended) with additional imported material or with reclaimed road materials.
Before using any alternative materials, compliance with the following properties as applicable shall be ascertained:
• The durability of the material.
• No deleterious minerals or hazardous material and chemicals present.
• The strength characteristics for relation to the proposed use of the material, such as ACV, 10 % FACT, CBR, ITS and the like.
Sufficient tests shall be carried out to verify appropriate compliance with the above aspects and to ensure that the alternative material is compliant for
its intended use in the earthworks or pavement layers.
For alternative materials identified by the Employer, initial negotiations or enquiries shall be conducted by the Employer about the availability of
the material, price and conditions for procuring. The Employer may then decide to procure the material, where after the Contractor shall be
responsible for producing, stockpiling and delivery of the material to the road.
Alternatively, when specified in the Contract Documentation, the Employer will not procure the alternative material and the Contractor shall be
responsible for all contractual and legal matters pertaining to ordering, processing, stockpiling, loading, delivering and paying for alternative
materials obtained from any alternative sources.
The Contractor shall also ensure that the site, property and the works where the material is sourced comply with all the applicable safety
requirements.

Should the Contractor wish to propose the use of any alternative materials to replace the specified materials then sufficient laboratory test results,
together with a method statement stating how the material will be sourced, placed and processed, shall be submitted for review to the Engineer
to determine that the Contractor’s proposal meets the Employer’s requirements.
There are no performance based systems required for Section A4.5.
A4.5.5 MATERIALS
A4.5.5.1 General
The material specifications given in Clause A4.1.5 shall also apply to any alternative materials produced for use in the earthworks and pavement
layers. These material specifications are the required specifications for the alternative materials finally processed and placed in the road.
Crushing and screening or modification, etc of the materials may be required to comply with these specifications.
A4.5.5.2 Construction and demolition material

The various types of construction and demolition material compliant for use in earthworks and pavement layers are given in
Table A4.5.5-1.
Table A4.5.5-1: Usage of construction and demolition material
Type of material Appropriate usage
Fill layers, the selected and possibly the subbase

layers if the grading is compliant or when the
Crushed concrete
grading can be improved by the addition of other
approved material
Broken concrete and clay bricks and mortar, mixed

Fill and selected layers
crushed bricks, concrete and clay roof tiles, and glass
Uncrushed concrete and hard burnt clay bricks Pioneer layer
Construction and demolition material to be used for the construction of earthworks and pavement layers shall not contain any of the following
materials:
• Timber,
• Reinforcing steel or mesh, steel, iron or other scrap metal,
• Asbestos products,
• Plastic and PVC materials,
• Dry walling materials,
• Pipes,
• Aluminum,
• Window and door frames,

• Laminated glass,
• Slate roof tiles,
• Electrical fittings,
• Insulation materials, and
• Carpets.
All such contaminant materials shall be removed before the material is produced by crushing, if applicable, loaded and hauled to the road.
A4.5.5.3 Industrial operations material

Material obtained from Industrial operations containing organic materials, textiles, plastics, petroleum products, hazardous chemicals or any other
deleterious material (metals, sludge and so forth) shall not be used.
Materials from industrial operations that have a record of being used are detailed below.
a) Slag from the production of ferrous and non-ferrous materials

Some industrial slags may be compliant for use in fill layers, the selected and the subbase layers, either on their own or blended with sand or
gravel or soil material. Slag is generally not compliant for a crushed stone base layer due to the porosity and high surface voids of the slag.
The most common industrial slags are granulated blast furnace slag and steel slag from the production of iron and steel respectively. Granulated
blast furnace slag is a stable material and generally does not require weathering as it does not contain free lime (CaO). However, unlike blast
furnace slag, steel slag shows volumetric instability mainly due to the presence of free magnesium oxide (MgO) and free lime (CaO). In the
presence of water, these compounds hydrate expansively.
Due to its expansive properties the use of steel slag shall not be considered in the works unless conditions pertaining to its use are agreed to.
When steel slag is proposed, the Contract Documentation shall include the expansion tests to be carried out and what test limits shall apply for
the proposed use of the steel slag, and any pre-treatment that may be required.
b) Ash
Ash from coal burning power plants is generally compliant for fill layers. It may also be compliant for the pavement layers of lower category roads,
or for the wearing course of unsealed roads. However, the properties of ash vary considerably from one source to another, and any ash proposed
for use in the works shall be tested for compliance with the relevant material specifications given in Clause A4.1.5.
Pulverised fuel ash (PFA), also known as fly ash, is a very fine material that is difficult to compact and may liquefy under wet conditions. It may
be compliant for use in fill provided the necessary precautions are taken during the placing, processing and compaction operations but it shall not
be used without the written approval of the Engineer.
Furnace bottom ash (FBA) can generally be used for fill layers and possibly for the lower pavement layers.
Ash generates dust that shall be contained during transport, placing and compaction.
A4.5.5.4 Mining operations material

Material obtained from mining operations shall be free from hazardous material and other unwanted materials such as timber, metal, plastic or
organic substances. The material shall also comply with the specifications for deleterious minerals in Clause A4.1.5.17. Depending on the material
quality and the grading of the material it can be compliant for use in fill layers and in the pavement layers.
As it comprises sand, gravel or rock or a combination of these natural materials, it shall be used in the same manner as any other naturally
occurring road construction material.
Stockpiles of material left over from the ore processing operations and mine dumps are generally non-compliant for use due to their fine grading
and the chemical contamination that is often present.
A4.5.5.5 Hazardous material

The following materials are considered hazardous in road construction, and shall not be used in the works or be present in any of the layers:
• Acid in liquid form,
• Free asbestos,
• Animal carcasses,
• Batteries,
• Chemicals and containers,
• Disinfectants,
• Fertilizers,
• Fireworks,
• Fuel,
• Gas cylinders,
• Insecticides and pesticides,
• Medical waste,
• Oils,

• Paint and solvents,
• Pharmaceuticals,
• Radioactive material, or
• Weed killers.

It is the Contractor’s responsibility to ensure that the alternative material including the furnishing, loading, hauling, further stockpiling if applicable,
shall comply with the material specifications.
Any approval or consent given previously for the use of any alternative material shall be withdrawn, when the material no longer complies with the
specifications anymore.

Construction equipment to source the alternative materials shall comply with requirements of Clause A1.2.6 of Chapter 1.

A4.5.7.1 Separation and selection of material
Compliant road construction material shall be separated from unwanted contaminant material specified in Clause A4.5.5.2 and hazardous material
in Clause A4.5.5.5. The road construction material shall have no visible signs under the naked eye of any unwanted material.
Material that is too large for acceptance by the crusher, such as pieces of concrete, shall be broken down to smaller sizes by conventional or
handheld equipment.
A4.5.7.2 Producing the material by crushing and screening

Alternative materials, except ash and slag material from commercial suppliers, are seldom compliant for direct use in the road. It will generally
require crushing, or screening, or crushing and screening.
For producing by crushing or by crushing and screening, and for the stockpile of the produced alternative materials, Clauses A4.1.7.2k) and
A4.1.7.3 respectively shall apply.
A4.5.7.3 Use of the material

The Engineer shall have full control of the use of all alternative materials. The Contractor shall plan the operations and particularly the separation
of unwanted material, breaking down of oversize material, and crushing and screening, in such a manner that any alternative material is used to
the best advantage of the Employer. This means that no material shall be unnecessarily processed, produced or hauled.
A4.5.8 WORKMANSHIP
The Engineer and the Contractor, shall determine and agree on the testing protocol and frequency of the applicable process control tests on any
alternative material being used, to ensure that the quality of the materials produced complies with the specified requirements for the particular
layer for which it will be used.
In addition to the standard tests used for the testing of earthworks and pavement layers materials, the following material tests shall be carried out
where applicable:
• Chemical analysis by a recognised chemical laboratory to determine the presence and quantity of deleterious minerals and
hazardous material.
• Determine the amount of expansion and degree of disintegration of the material when immersed in water for a prolonged period.
The required soaking period will depend on the particular material.
• Hardness and durability tests depending on the use of the material. The relevant material properties specified in Clause A4.1.5 shall
be applicable unless otherwise specified in the Contract Documentation.
• Determine the presence of unwanted material and hazardous material listed in Clauses A4.5.5.2 and A4.5.5.5 respectively.
Measurement, testing, and evaluation of all individual components and constructed products shall be in accordance with the methods prescribed in
this Section or in Chapter 20 as relevant.

B4.5 ALTERNATIVE MATERIALS
CONTENTS
B4.5.1 SCOPE
B4.5.2 DEFINITIONS
B4.5.3 GENERAL
B4.5.5 MATERIALS

B4.5.8 WORKMANSHIP
B4.5.1 SCOPE
This Section covers the work requirements for sourcing alternative materials that can be used for the construction of road earthworks and
pavement layers, and which are obtained from sources other than from borrow pits and quarries, or from cuttings, box cuts and designated
excavations, or from the existing road or from commercial sources.
B4.5.2 DEFINITIONS
B4.5.3 GENERAL

B4.5.5 MATERIALS


B4.5.8 WORKMANSHIP

C4.5 ALTERNATIVE MATERIALS
(i) Preamble
The following required activities will not be measured and paid for separately and the Contractor shall include the cost thereof in other items as
deemed appropriate:
1. Taking of samples and laboratory testing of alternative materials identified by the Contractor to prove compliance with the specified
properties.
2. For alternative materials identified and sourced by the Contractor, the removing of unwanted contaminant and hazardous material, breaking
down oversize material, crushing, screening and separation, all as required, and for loading, hauling and off-loading.
• Alternative materials identified by the Employer
For alternative materials that must still be separated, cleaned, broken down, produced by crushing or crushing and screening as
applicable, and then stockpiled, measurement and payment shall be made according to the applicable items in
Section C4.1. Procurement of the material by the Contractor, if specified in the Contract Documentation, shall be paid separately in
item C4.5.3 hereunder. Loading and hauling the material to the road shall be measured and paid for in Chapter 5.
Alternative materials that are already produced into the correct gradation compliant for use in the road layers and that are sold as a
commercial material, shall be measured and paid for in accordance with Section 4 item C4.4.1. The cost for procuring the alternative
material, for loading and hauling it to the road shall then be included in the tendered rate.
• Alternative materials identified and sourced by the Contractor
Alternative materials identified and sourced by the Contractor shall be measured and paid for in accordance with item C4.4.2 as for
commercial materials. Procuring the alternative material, producing, crushing and/or breaking down and stockpiling as required, for
loading at the source and hauling it to the road irrespective of the haul distance shall then be included in the tendered rate.
C4.5.1 Additional material investigations
C4.5.1.1 Cost of sampling and laboratory testing provisional sum
C4.5.2 Removing unwanted material from alternative materials identified by the Employer
C4.5.2.1 Contaminant material provisional sum
C4.5.2.3 Hazardous material provisional sum
C4.5.3 Cost to procure alternative materials identified by the Employer
C4.5.3.1 Cost of procuring provisional sum

D4.5 ALTERNATIVE MATERIALS
CONTENTS
D4.5.1 SCOPE
D4.5.2 GENERAL

South Africa
COTO
Officials
Standard Specifications for

Road and Bridge Works for
South African Road Authorities

CHAPTER 5: EARTHWORKS AND
PAVEMENT LAYERS:
CONSTRUCTION
October 2020

FOREWORD

Published by:

industry.
Document versions:
Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 5: EARTHWORKS AND PAVEMENT LAYERS: CONSTRUCTION .................................................... 5-1
5.1 ROADBED .......................................................................................................................................................... 5-1
PART C: MEASUREMENT AND PAYMENT .................................................................................................................................................... 5-11
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES ....................................................................................................................... 5-19
5.2 FILL .................................................................................................................................................................. 5-20

5.3 ROAD PAVEMENT LAYERS........................................................................................................................... 5-36

5.4 STABILISATION .............................................................................................................................................. 5-63

5.5 RECONSTRUCTION OF PAVEMENT LAYERS ............................................................................................. 5-78

PART D: GUARANTEES AND COMPLIANCE CERTIFICATES ..................................................................................................................... 5-103
CHAPTER 5: EARTHWORKS AND PAVEMENT LAYERS:
CONSTRUCTION
5.1 ROADBED
CONTENTS
A5.1.1 SCOPE
A5.1.2 DEFINITIONS
A5.1.3 GENERAL
A5.1.5 MATERIALS
A5.1.8 WORKMANSHIP

A5.1 ROADBED
A5.1.1 SCOPE
This Section covers the work requirements for normal roadbed treatment. This is all work in connection with the preparation and compaction of
the roadbed, the removal to spoil of material not approved for use in the roadbed and for the replacement of the spoiled roadbed material. Normal
roadbed treatment includes dealing with collapsible subgrades, unsuitable material and clay.
Specialist roadbed treatment shall be dealt with in accord with Clause A5.1.3.3.
The following Sections contain relevant specifications for Section A5.1:
• Section A1.2 of Chapter 1 – General requirements and provisions
• Section A1.5 of Chapter 1 – Accommodation of traffic
• Section A1.6 of Chapter 1 – Clearing and Grubbing
• Chapter 4 – Earthworks and pavement layers: Materials
• Section A12.3 of Chapter 12 – Ground improvement
• Section A12.10 of Chapter 12 – Hard excavation by blasting
A5.1.2 DEFINITIONS
The relevant definitions elsewhere in the standard specifications are applicable. Additional definitions for this Section follow.
Batter - a slope inclined upwards or downwards between the outer edge of a constructed platform area and the outer edge of a second constructed
platform area located above or below the first constructed platform. The slope gradient shall be as indicated in the Contract Documentation.
Clay activity - clays are either inactive, normal or active. The activity of clay (A) is measured by the ratio of the plasticity index (PI) to the
percentage passing the 2µm (P0,002) sieve opening.
• A clay is active when (A > 1,25)

• A clay is normal when (0,75 < A < 1,25)
• A clay is inactive when (A < 0,75)
Potential expansiveness of clay is also dealt with in TRH9 (van der Merwe method).
Collapsing soil or sand - a soil with a collapsible grain structure. It is a soil which can withstand relatively large imposed stresses with small
settlements at a low in-situ moisture content but exhibits a decrease in volume and associated additional settlement with no increase in the applied
loading if wetting up occurs. The change in volume is associated with a change in soil structure (the collapse of the grain structure).

Collapse settlement - is the term applied to the additional settlement which occurs due to the wetting up of a partially saturated collapsible soil
under load. This collapsing soil phenomenon shall not be confused with consolidation or compaction, since no water is dissipated from the soil,
but the collapsing soil absorbs water and progressively loses strength.
Normal roadbed treatment - normal roadbed treatment is treatment that does not need to be designed by specialist geotechnical engineers nor
does it need to be constructed using specialist geotechnical construction equipment.
Roadbed - the constructed, treated or improved natural in place material on which the fill or the pavement layers is constructed directly. The
roadbed is constructed prior to the construction of the fill or pavement layers.
Road prism – is the area disturbed during previous or new road construction. The road prism extends between the top of slopes where in cut and
between the bottom or toe of slopes where in fill. Where the road cross section is in cut and fill, the road prism shall extend between the top of the
cut slope and the bottom or toe of the fill slope. Additionally, the road prism shall include the median width and all side drains when the nearest
edge of the side drain is located within 0,5 m of the top of the cut slope or located within 0,5 m of the bottom or toe of the fill slope.
Roller-pass (conventional roller) - an area will be taken to have received one roller-pass when a roller has passed over the area once. Additional
passes made as a result of nominal overlapping of at least 200 mm so as to ensure full coverage of the area, shall not be taken into account.
Roller-pass (high-energy impact compactor or roller HEIC) - an area will be taken to have received one roller-pass when an HEIC has passed
over the area twice. Additional passes made as a result of nominal overlapping of at least 200 mm so as to ensure full coverage of the area shall
not be taken into account.
Note: With the continued enhancement of HEIC compaction technology this definition may need to be adjusted or augmented to suit the
compaction equipment. Any adjusted definition shall be included in the Contract Documentation.
Side-cut or benching - the excavation of material to form benches or steps. Suitable excavated material is bladed or placed directly by excavator
or dozer into the final position of the material. The material is used for the construction of a roadbed fill, a fill widening or a backfill behind a
retaining structure without it having to be loaded and hauled to the place of final use. Material excavated in this manner is termed side-cut or
benching to fill.
Subgrade - the completed earthworks within the road prism before the construction of the pavement layers. This comprises the treated in-situ
material of the roadbed and the fill material.
A5.1.3 GENERAL
A5.1.3.1 Roadbed material investigation
The geotechnical information provided in the Contract Documentation for the roadbed reports the results of site investigations including the
excavation of test pits and/or drilling, and laboratory tests conducted by or on behalf of the Employer. This provides information as to the quality
of the roadbed material and the type of roadbed treatment required.
If not already specified in the Contract Documentation, the Engineer shall instruct the Contractor regarding the different types of normal roadbed
treatment or ground improvement, required in terms of Section A5.1 and Section A12.3 of Chapter 12. Normal roadbed treatment excludes
specialist roadbed treatment listed in Clause A5.1.3.3.
The Engineer shall give final instructions regarding any additional investigation and testing requirements and the treatment of the roadbed
materials prior to the commencement of the programmed roadbed construction period. If any undocumented roadbed conditions are found during
construction, the Engineer shall be notified immediately so that any further instructions that may be required, can be issued.
The road prism must be surveyed and correctly staked before any roadbed related operations commence to ensure that the correct extent of
roadbed is demarcated for treatment.
A5.1.3.2 Roadbed construction

The Contractor shall take due cognizance when programming roadbed construction as to whether the work may be able to be carried out as full-
width construction or if the work may only be able to be done as partial-width construction or carried out under other restrictive conditions.
Clauses C1.1.3.2 and A1.2.3.23 of Chapter 1 are applicable for roadbed construction that takes place as partial-width construction or takes place
under restrictive conditions.
A5.1.3.3 Ground improvement or specialist roadbed treatment

Roadbed ground improvement requiring specialist geotechnical input is dealt with in Section A12.3 of Chapter 12. The various types of ground
improvement specified for the roadbed are:
• Geotechnical grouting,
• Jet grouting,
• Compaction grouting,
• Dynamic compaction,
• Rapid impact compaction,
• Vibro-compaction,
• Underpinning,
• Preloading and monitoring, and
• Geosynthetics

A5.1.5 MATERIALS
A5.1.5.1 Remove unwanted material
Prior to construction or treatment of the roadbed, the in-situ roadbed material shall not contain any of the following materials listed hereunder.
These unwanted materials shall be removed to a designated spoil site.
• Organic materials, grass and shrubs;
• Wood chippings, tree bark and roots;
• Plastic (bags, polystyrene and so forth);
• Refuse or other non-compliant material;
• Free asbestos; or
• Any of the hazardous material as listed in Clause A4.5.5.5 of Chapter 4.
A5.1.5.2 Topsoil
Topsoil shall be obtained from wherever suitable topsoil material occurs within the road prism ahead of the roadbed construction and within the
road reserve as detailed in the Contract Documentation and as specified in Clause A1.6.7.6 of Chapter 1.
A5.1.5.3 Collapsing soil material

The following types of material exhibit a collapsible structure and may form part of the roadbed in some areas as detailed in the Contract
Documentation:
• Certain types of Kalahari sands, other aeolian sands and transported sands.
• Some alluvial and sedimentary soils.
Features most commonly associated with collapsible soils include:
• An open soil structure;
• A high void ratio (‘void ratio’ is the ratio of ‘volume of voids to the volume of solids’);
• A low dry density;
• A high porosity;
• Geologically young or recently altered deposit;
• Low inter-particle bond strength.
Table A5.1.5-1 provides an indication of the collapse potential of a soil in terms of key soil properties.
Table A5.1.5-1: Soil property collapse potential (CP) indicators
Soil Property CP indicators
Maximum dry density / MDD (kg/m3) < 1600
% passing 2,0 mm and retained on 0,075 mm sieve opening > 60 %
% passing 0,075 mm sieve opening < 20 %
In place relative density as % of MDD < 85 %
Where required an inspection pit shall be dug and the material sampled. An undisturbed sample for carrying out a single oedometer test shall be
taken. The single oedometer test, also known as the collapse potential (CP) test, shall be performed to assess collapse potential. Table A5.1.5-2
summarises the potential for collapse in terms of the single oedometer test result. The undisturbed sample for the oedometer test shall be taken
at a depth of between 0,8 m and 1,0 m below the material depth detailed in Table A4.1.5-2 of Section A4.1 of Chapter 4.

Table A5.1.5-2: Potential for collapse
Test result range for the single oedometer test Collapse Potential
0–1% No potential
1%–5% Moderate potential
5 % - 10 % Definite potential
10 % - 20 % Severe potential
> 20 % Very severe potential
Some collapsing soils exhibit two separate optimum moisture content (OMC) values with two separate maximum dry densities. The collapsibility
of these soils is very sensitive to small increases or decreases in compaction moisture content.
A5.1.5.4 Spoil material

The roadbed may contain material that is unsuitable for use because the quality of the material is unacceptable. This material shall be excavated,
loaded and hauled to designated spoil sites as instructed by the Engineer. When designated spoil sites are not available temporary spoil stockpiles
may be permitted with the prior consent of the Engineer.
The material so removed shall be replaced with fill material or pioneer layer material as instructed by the Engineer.
A5.1.5.5 Pioneer layer material

The properties of material for a pioneer layer are specified in Clause A4.1.5.3 of Chapter 4.
A5.1.5.6 Geosynthetic materials

Reference shall be made to Section A12.11 Geosynthetics of Chapter 12, for the specification, application and types of geosynthetic material to
be used for a specific application.

Construction equipment to carry out roadbed treatment shall comply with the requirements of Clause A1.2.6 of Chapter 1.
High energy impact compactors (HEIC) shall be equipped with functioning continuous impact response metering and GPS when specified in the

A5.1.7.1 Clearing and grubbing
The entire roadbed shall be cleared and grubbed as specified in Section A1.6 of Chapter 1 ahead of any topsoil being removed. Any hazardous
material uncovered, shall be disposed of in terms of Clause A1.6.7.7 of Chapter 1.
The clearing and cutting of trees is specified in Section A1.6 of Chapter 1.
The road prism shall be cleared and grubbed 2,0 m wider than the road prism width. Material obtained from clearing and grubbing shall be removed
to a temporary stockpile site within the road reserve or removed from site as detailed in the Contract Documentation.
The burning of material on the site of the works shall not be permitted.
Areas within an existing road prism will normally not require clearing and grubbing.
The removal of buildings and structures is specified in Section A1.6 of Chapter 1 and the removal of materials generally found in urban areas such
as kerbs, road-edging, utility structures and paved sidewalks are specified in Section A4.3 of Chapter 4.
A5.1.7.2 Removal and conservation of topsoil from roadbed

After clearing and grubbing, topsoil shall be excavated and stockpiled as specified in Section A1.6 of Chapter 1, but only after the Engineer has
confirmed that the removal of topsoil and the stockpiling thereof, is required.
The topsoil shall be excavated and stockpiled for later top-soiling of the fill and cut slopes. The requirements of Section A1.6 of Chapter 1 for the
removal of topsoil shall be complied with.
A stockpile site shall be prepared at the designated area prior to removing any of the required topsoil in accordance with the provisions of Clause
A4.1.7.3 of Chapter 4.
Topsoil shall be stockpiled in separate loose heaps not exceeding 2,0 m in height, unless specified otherwise in the Contract Documentation. The
haul trucks shall not be driven over the top soil material and any compaction of the topsoil shall not be permitted.
A5.1.7.3 Normal roadbed treatment

a) Construction overview
The method of processing and compacting the roadbed and fill material as part of normal roadbed treatment, or the class of compaction, shall be
specified in the Contract Documentation or be instructed by the Engineer in advance.
The classification of material as hard material or in the case of LEC, intermediate material, to compensate the Contractor for the cost of excavation

thereof, shall not be taken into consideration for any additional compensation when used in the compacted fill.
When the roadbed to be treated is located on a slope that is steeper than 1 (one) vertical to 10 (ten) horizontal, the roadbed treatment shall be
benched as specified in Clause A5.2.7.3 and in the Contract Documentation. The minimum depth of the specified roadbed treatment shall be
complied with for the full extent of the treatment.
Ground improvement roadbed treatment is not normal roadbed treatment, but specialist roadbed treatment and is specified in Chapter 12.
b) Removal of unsuitable roadbed material
Any roadbed material which is of unsuitable quality shall be removed to spoil to such widths and depths as instructed by the Engineer. The
unsuitable material shall be disposed of as detailed in the Contract Documentation or as instructed by the Engineer. The excavated roadbed
material shall then be replaced with approved, imported fill material, compacted to the specified density.
The Engineer may instruct that material that is unsuitable due to being unstable be removed and replaced with approved material. The Contractor
shall implement adequate temporary drainage measures as per instruction from the Engineer, ahead of the removal to spoil of the unstable
material. The instruction by the Engineer must clearly state the depth of the material to be removed, contain an assessment in respect of the
stability of the material and ensure that suitable construction equipment is available.
After completion of the removal of any unstable material to the specified line and depth in accordance with the Engineer’s instructions, it may still
be necessary to remove some stable material. This material will also be classified as ‘unstable’ material, for measurement and payment purposes
only, if the thickness of the stable material to be removed is less than 200 mm. If the thickness to be removed exceeds 200 mm then the stable
material will remain classified as stable material taken to spoil.
c) Percentage of maximum dry density (MDD)
Any section of the roadbed material that is classified as being suitable for use in-situ, but the material fails to meet density requirements, shall be
scarified, watered and compacted to the depth and to the percentage of MDD specified in the Contract Documentation. In the absence of a
specified depth, the depth of roadbed treatment shall be 150 mm. If necessary, roadbed material may have to be scarified and temporarily bladed
to windrow to allow for compaction in layers in order to achieve the specified compaction density throughout the specified depth of treatment.
Where any additional material has to be imported to make up the required level and layer thickness, and where the thickness of the layer of
imported material would be less than the specified layer thickness after compaction, then the roadbed material shall first be scarified. The additional
imported material shall then be placed, blended with the scarified roadbed material and compacted to the full specified depth of that roadbed layer.
d) Roller-pass compaction
Where the percentage compaction cannot be satisfactorily determined by way of testing the in-situ density due to the nature of the material, the
Engineer shall instruct that the material be compacted by a specified number of passes. The number of passes shall be carried out by a single
type of roller or by a combination of various types of rollers. The Engineer shall issue instructions regarding the required number of passes for
each type of roller being used.
A trial section shall be constructed to determine the best type of rollers or combination of rollers and the required number of roller-passes for each
roller being used.
The Contractor shall use one, or a combination of any, of the following rollers:
• Grid roller;
• Impact roller;
• Pad-foot vibratory roller;
• Smooth drum vibratory roller;
• Pneumatic roller;
• High energy impact compactor (HEIC); or
• Any other suitable roller.
This roller-pass compaction shall normally be carried out at the in-situ moisture content. No rigid control of the moisture content will be exercised
during compaction. The Contractor shall nevertheless prove to the Engineer that every possible endeavour is being made to take advantage of
favourable soil-moisture conditions and to carry out such roller-pass compaction in so far as is possible during periods when the roadbed is neither
excessively dry nor excessively wet.
The Contractor shall consult the Engineer as to when conditions are favourable for compaction and where such compaction shall be done at any
particular time. The Engineer shall instruct and then compensate the Contractor to water the roadbed when the roller-pass compaction cannot be
programmed to be carried out at a time when acceptable moisture conditions exist.
e) Compaction of collapsible soil
(i) General
The type of treatment of any portion of the roadbed that has a collapsible soil structure shall be specified in the Contract
Documentation.
(ii) Soil collapse construction
The measurable criteria to confirm that soil collapse has taken place, such as percentage of MDD, the in-situ measured CBR (by
DCP), the amount of collapse settlement and so forth, shall be specified in the Contract Documentation.
(iii) Non wetting-up roadbed collapse
The non wetting-up collapsible roadbed material;
• The material can be compacted in-situ using conventional rollers and/or HEIC rollers. The soil shall be collapsed at the in-
situ moisture content.
• The material to be collapsed can alternatively be temporarily excavated to stockpile and then imported from the stockpile in
controlled compacted layers.

A trial section shall monitor and establish all or some of the following criteria as specified in the Contract Documentation.
• The existing in-situ DCP-determined CBR strength (pre-construction);
• Confirm the compaction equipment or combination of compaction equipment required;
• A correlation between settlement, density and DCP-determined CBR strength for compaction control;
• The minimum required number of compaction passes to ensure collapse settlement;
• The moisture content and the percentage of MDD; and
• The DCP-determined CBR (post-construction) at the depth specified.
(iv) Wetting-up roadbed collapse
The wetting-up and compaction of a roadbed trial section for the collapse thereof shall be divided into construction phases:
• Determine the pre-construction moisture contents and then after each controlled addition of water.
• All moisture contents are to be determined along the length and the full collapse depth of the trial section. This is to establish
and verify uniform moisture sections for collapse treatment;
The trial section shall monitor and establish all or some of the following criteria as specified in the Contract Documentation:
• The existing in-situ DCP-determined CBR strength at different depths (pre-construction);
• Determine the moisture contents and DCP-determined CBR strengths after completion of each wetting and compaction cycle
during the construction of the trial section;
• Establish the amount of vertical settlement or collapse by taking sufficient levels before, after completion of each wetting-
up/compaction phase and after the completed construction of the trial section for each uniform moisture section.
• The minimum required number of compaction passes, compaction equipment and moisture content required to ensure
compliance with the specified collapse settlement and/or the required DCP-determined CBR, post-construction.
f) Hard material
Where detailed in the Contract Documentation, or as instructed by the Engineer, the roadbed shall be treated in-situ by breaking up formations of
hard materials in order to achieve a uniform standard of compaction and to improve the subsurface drainage ahead of the fill or the road pavement
layers.
Treatment in-situ shall consist of ripping the roadbed, or drilling and blasting the roadbed using explosives, or drilling and splitting the roadbed
using non-explosive, expansive, rock-breaking products. The depth of ripping or drilling shall increase uniformly from the centre of the roadbed to
the edges, on cambered sections of road.
(i) In-situ treatment by ripping
Unless indicated otherwise in the Contract Documentation, or instructed by the Engineer, the depth of ripping in the centre of the
roadbed shall not be less than 300 mm and at the edges of the roadbed not less than 500 mm.
On super elevation sections or cross-fall sections the in-situ treatment shall have a cross-fall parallel to the pavement cross-fall
and a uniform minimum depth of 400 mm.
Shales and mudstones shall also be treated in-situ as described above or removed to the required depth if so specified in the
After ripping, the hard roadbed material shall be broken down by rolling until the maximum dimension of any material fragment
does not exceed 200 mm. The material shall then be compacted by means of a specified number of passes by a selected type of
roller or by a combination of various rollers.
(ii) In-situ treatment by drilling and rock breaking
Unless indicated otherwise in the Contract Documentation, or instructed by the Engineer, the depth of drilling and rock breaking
shall not be less than 700 mm at the centre of the roadbed and not less than 1000 mm at the edges of the roadbed.
On super elevation sections or cross-fall sections, the in-situ treatment shall have a cross-fall parallel to the pavement cross-fall
with a minimum depth of 850 mm.
After drilling and rock breaking, the hard roadbed material shall be broken down by rolling until the maximum dimension of any
material fragment does not exceed 200 mm. The material shall then be compacted as specified by means of a number of roller-
passes using a selected type of roller or a combination of various rollers. The Contractor shall determine the drilling pattern to
ensure that the amount of breaking down required during compaction is less than 5 %.
Any surplus material resulting from bulking after in-situ treatment, shall be removed and disposed of or utilized elsewhere as
g) Inactive clay and normal clay
Inactive clays and normal clays in the roadbed that heave or settle during a three roller-pass trial compaction shall be treated using one of the
following three methods, as specified in the Contract Documentation.
A trial section shall be constructed of the specified roadbed treatment, to clearly establish the construction technique to be applied as well as to
confirm the correct construction equipment and the required number of roller-passes required.
The trial section shall also clearly establish the visual and/or laboratory testing to be done. Upon completion of the trial section the Engineer shall
instruct the Contractor regarding the type and amount of testing.

(i) Material modification
The in-situ roadbed material shall be shaped to line and level. A layer of approved material, thickness as specified in the Contract
Documentation, shall be imported and spread out across the top of the pre-shaped roadbed.
The imported layer shall be thoroughly blended with the inactive/normal clay to the depth as specified in the Contract
Documentation using appropriate construction equipment and then compacted to comply with the specified MDD or to comply
with the specified number of roller-passes and compaction requirement.
(ii) Lime modification
The in-situ roadbed material shall be shaped to line and level. The amount of road lime shall be as specified in the Contract
Documentation. This amount shall not be less than 2 % by weight. The road lime shall then be evenly spread over the shaped
roadbed. Laboratory testing prior to construction shall establish the required lime content and the ideal maturing period to achieve
a maximum reduction of the plasticity index (PI). The Engineer shall then instruct the Contractor accordingly.
The lime shall be mixed in-situ into the roadbed material to the specified depth in the Contract Documentation or as instructed by
the Engineer using a suitable rotovator or recycling machine or by making use of other appropriate construction equipment such
as a motor grader and plough. The thickness of mixing should be limited to a maximum of 200 mm. Adjacent mixing strips shall
be overlapped by at least 150 mm to avoid any material not being treated.
During initial mixing and pulverisation, it may be necessary to add water when the in-situ material is below OMC, in order to ensure
that the lime modifies the material.
Following each mixing pass the material shall be trimmed and lightly compacted using single roller-pass compaction or as
instructed by the Engineer, with a smooth wheeled roller or pneumatic tyre roller or other suitable roller as determined during the
construction of a trial section, in order to ensure the correct processing depth throughout the operation. Once initial mixing and
the addition of water is complete, the material shall be trimmed and lightly compacted with two roller-passes and then left for a
maturing period which shall be between 24 hours and 72 hours as determined by the laboratory.
Following the maturing period, re-mixing and the final moisture content adjustment shall take place. The moisture content should
be as close as possible to the OMC for the material. The roadbed material shall then be compacted to either the specified MDD
or to the specified roller-pass compaction requirement.
(iii) Removal of material
The clay material shall be removed and replaced with approved material to a maximum depth of 450 mm as specified in the
Contract Documentation. The approved material shall be compacted to the specified MDD.
h) Active clay
Treatment of active clays shall be by means of Alternative 1 or by means of Alternative 2 hereunder. The method to be used shall be as specified
in the Contract Documentation or as instructed by the Engineer.
(i) Alternative 1 - Roadbed construction using lime
Laboratory testing prior to construction shall confirm the required lime content and the ideal maturing period in terms of the
maximum reduction of the plasticity index (PI).
A trial section shall then be constructed to clearly establish the construction technique to be applied as well as to confirm the
correct construction equipment to be used and the required number of roller-passes.
The in-situ material shall be shaped to line and level for the section of roadbed with active clay and the roadbed shall then be
processed in 3 phases as specified below.
• Phase 1 Mix first 50 % of lime
The section of in-situ roadbed with active clay shall be ripped to a depth of 250 mm or to a depth as specified in the Contract
Documentation and 50 % of the required total road lime content, as determined by the laboratory testing, shall then be mixed
in to the full depth using a rotovator or a recycling machine. Due to the nature of active clay the use of a motor grader and/or
plough will not achieve the required degree of mixing when used on their own. During this mixing process the Contractor
shall ensure that all the clods of clay are broken down. If necessary, a pad foot roller can also be used to help break up the
clay clods.
After the mixing and breaking down process has been completed, water must be added if required, to ensure that the moisture
content shall be close to 50 % of the optimum moisture content. The layer shall then be sealed with a single roller-pass
compaction using the appropriate roller as established during the construction of a trial section.
• Phase 2 Maturing period
The treated roadbed clay material shall then be left for at least 48 hours or any longer period as determined by the laboratory
to allow the first amount of lime to react with the material to make the material more workable.
• Phase 3 Mix balance of lime and compact
After the maturing period, spread the remaining 50 % of the lime, rip the 250 mm thick roadbed layer and mix in the lime
using a rotovator, a recycling machine or a grader and plough as determined during the construction of a trial section.
After this mixing process has been completed water must be added to ensure that the moisture content shall be close to 50
% of the optimum moisture content. The roadbed material shall then be compacted as specified in the Contract
Documentation or as instructed by the Engineer after construction of a trial section.
During the final compaction process the roadbed layer shall be shaped to the correct design levels and camber or cross-fall
to ensure that the compacted surface is able to drain. No low spots shall exist where water can be trapped beneath the fill
on top of the compacted and treated active clay roadbed material.
(ii) Alternative 2 - Roadbed construction by removal of active clay
The heaving clay in the roadbed shall be removed down to the bottom of the clay layer, or to a minimum depth of 750 mm below
natural ground level, or to a depth as specified in the Contract Documentation. The material shall be loaded, hauled and then off-
loaded at a designated spoil site.

The removed material shall be replaced with compliant material and be compacted to the specified percentage of MDD as per the
Moisture content fluctuations for both alternatives within the road prism must be restricted. This shall be achieved by constructing a flattened side
batter such as 1 (vertical):3 (horizontal), or by placing and compacting additional clay material adjacent to the standard road side batter as detailed
i) Construction of a pioneer layer
Where fill is to be constructed across water-logged or soft clayey ground, that exhibits excessive movement under normal compaction equipment
and haulage trucks (unstable material), and such conditions preclude the effective compaction of the bottom fill layers, or the effective removal of
the material to spoil, a pioneer layer shall be constructed directly over this material as detailed in the Contract Documentation or as instructed by
the Engineer. The pioneer layer shall be constructed by dumping successive loads of material compliant with Clause A4.1.5.3 of Chapter 4 and
spreading the material uniformly to a thickness which is just sufficient to provide a stable working platform for constructing the subsequent fill
layers.
Appropriate light hauling equipment shall be used and end-tipping shall be employed for placing the material. The layer shall be compacted by
using suitable compaction equipment without the water-logged roadbed material being overstressed. Pioneer layers shall not require compaction
to a controlled density.
Upon completion of the construction of the pioneer layer, the construction of a levelling course layer with an average compacted thickness of 200
mm shall normally be required to be constructed to line and level, using compliant fill material. The compacted density of the layer shall be as
instructed by the Engineer, but no more than a density of 90 % MDD.
A5.1.7.4 Special drainage measures, dewatering

Any waterlogged roadbed, such as saturated material overlying less pervious strata, shall first be drained by the installation of all permanent
surface and/or subsoil drainage detailed in the Contract Documentation or as directed by the Engineer, before any other construction may
commence on these sections.
A5.1.7.5 Dolomitic roadbed treatment

In dolomitic areas the roadbed treatment by the construction of a soil raft, or by any other appropriate treatment measure, shall be specified in the
Contract Documentation by a geotechnical Engineer.
A5.1.8 WORKMANSHIP
A5.1.8.1 Inspection of the works
The Engineer shall do routine inspections and conduct routine tests to determine whether the quality of material and workmanship provided,
complies with the requirements of the Contract Documentation.
A5.1.8.2 Compaction requirements

Compaction compliance shall be determined as follows:
• The in-situ measured density of the roadbed treatment complies with the specification when the results of at least 75 % of the in-situ density
tests, located as per the Contract Documentation of any lot, are equal to or exceed the specified values and no single density is more than
5 percentage points below the specified value.
• The roller-pass roadbed treatment complies with the specification when the agreed number of roller-passes have been observed and
recorded as being the same as that of the accepted trial section.
• The roadbed treatment of collapsing soils complies with the specification when the compaction of the collapsing soils is verified to yield the
same agreed results as obtained in the accepted trial section.
• The hard material roadbed treatment complies with the specification when the depth of blasting or ripping is confirmed as being in accordance
with the specification and the layer has been monitored and confirmed as being fully functional in terms of sub-surface drainage.
• There are no compaction density requirements for the pioneer layer. The pioneer layer complies with the requirements of the specifications
when movement or heaving of the pioneer layer under the load of conventional compaction equipment or of loaded haulage trucks has
ceased.
• The in-situ measured density of the levelling layer is compliant when results of at least 75 % of the in-situ density tests, located as per the
Contract Documentation, of any lot, are equal to or exceed the specified values and no single density is more than 6 percentage points below
the specified value.
A5.1.8.3 Construction tolerances

The roadbed shall be constructed to the dimensional tolerances specified below.
a) Levels
The level tolerances shall be as follows for the top of the roadbed.
In cases where the in-situ treatment of the roadbed supports a fill of more than 500 mm thick, the levels of the top of the treated roadbed shall not
be subject to any level tolerances other than that the roadbed shall at no point encroach more than 200 mm into the fill.
In cases where the in-situ treatment of the roadbed is beneath a fill of less than 500 mm thick, the levels of the top of the treated roadbed shall at
no point encroach more than 50 mm into the fill.
In cases where the in-situ treatment of the roadbed is in a cutting, irrespective of the type of material in the roadbed, and the pavement layers are
constructed directly on top of the treated roadbed, the treated roadbed shall be subject to the following tolerances as applied to the specified
design levels:
H90 = ± 25 mm Hmax = ± 35 mm

b) Width
The horizontal measurement taken from the centre line of the road to the edge of the roadbed treatment shall nowhere be 250 mm more than the
specified dimension when measured at roadbed level and nowhere should it be less than the specified dimension.

B5.1 ROADBED
CONTENTS
B5.1.1 SCOPE
B5.1.2 DEFINITIONS
B5.1.3 GENERAL
B5.1.5 MATERIALS
B5.1.8 WORKMANSHIP
B5.1.1 SCOPE
This Section covers the work requirements for normal roadbed treatment, which is all work in connection with the preparation and compaction of the
roadbed, the removal to spoil of material not approved for use in the roadbed and for the replacement of the spoiled roadbed material.
This Section therefore includes work with a component of labour. This work is included in Part A of this specification as well as the specification
of other sections.
This Part therefore only covers additional specifications for work to enhance the labour component of construction activities where specified.
B5.1.2 DEFINITIONS
Definitions as provided in Clause A5.1.2 shall apply.
B5.1.3 GENERAL

B5.1.5 MATERIALS


For roadbed, relative small cut to spoil operations and excavation of benches are suitable components for labour enhancement.
B5.1.8 WORKMANSHIP

C5.1 ROADBED
(i) Preamble
The tendered rate for each item shall include full compensation for providing, maintaining and decommissioning upon completion, of all the
construction plant, equipment, labour, tools, incidentals and supervision to carry out the activity or construct the works in the item, unless otherwise
stated.
(ii) Classification of materials for labour enhancement
Where excavation is done using labour enhancement methods, the Engineer shall classify excavated materials either as soft or intermediate, in
terms of Tables C5.1-1 and C5.1-2.
No hard material shall be measured under labour enhancement methods.
Table C5.1-1: Classification of excavated materials for labour enhancement
MATERIALS
DESCRIPTION
CLASSIFICATION
Soft
hand-swung tool
Intermediate
Table C5.1-2: Classification of materials in terms of consistency and shear strength for labour enhancement
NUMBER OF DCP BLOWS TO PENETRATE
CONSISTENCY
MATERIALS 100 mm *
CLASSIFICATION
Granular soil Cohesive soil Granular soil Cohesive soil **
*Only applicable to materials comprising not more than 10 % gravel of size less than 10 mm and materials containing no cobbles or
**This could be subjective depending on the moisture content of the cohesive material

deemed appropriate:
1. Staking of the road prism referred to in Clause A5.1.3.1.
2. Drainage and protection of the pavement layers from all damage that may occur for any reason until the Employer has taken over the Works.
3. Protection and repair as required of all existing and new roadside furniture, of all existing and new drainage structures and of all existing and
new infrastructure until the Employer has taken over the Works
4. Protection and repair as required of any other items adjacent to, over or under the road that are damaged by the Contractor’s vehicles, and
equipment, or by public traffic being accommodated on or alongside the Works, during the construction of the Works.
5. Repair of all damage to any new or existing structures, buildings, road furniture and services that may occur for any reason before, during or
after the construction of the roadbed up until the Employer has taken over the Works.
6. Provision of and/or the subsequent removal of all excess material after completion of the roadbed treatment.
(iv) Work in restricted areas
Clause C1.1.3.2b) of Chapter 1, specifies that all rates are to be inclusive.

(v) Items to be measured and paid for using payment items specified elsewhere in the specifications
For activities in Table C5.1-3 payment items specified in other Chapters or Sections of the specification, where they relate to work under this


Ground improvement (Specialist Roadbed Treatment) A5.1.3.3
applicable items
Remove unwanted material A5.1.5.1
applicable items
Topsoil A5.1.5.2 / A5.1.7.2
applicable items
Additional laboratory testing A5.1.3.1 / A5.1.7.3
applicable items
Loading and hauling material A5.1.5.4 / A5.1.7.3
applicable items
Clearing and grubbing A5.1.7.1
applicable items
Construction of stockpile site A5.1.7.2
applicable items
Fill material A5.1.7.3b)
applicable items
Hard material excavation A5.1.7.3f)
applicable items
Lime modification A5.1.7.3g)
applicable items
Drainage A5.1.7.4
applicable items
(vi) Determining the quantities

Before carrying out any construction work in connection with clearing and grubbing and the removal of topsoil, the Contractor, shall at no cost to
the Employer, take cross-sections at a maximum spacing of 20 m so as to determine the original ground line.
After completion of the topsoil removal the Contractor, shall at no cost to the Employer, take cross-sections at a maximum spacing of 20 m so as
to determine the new ground line and subsequently the quantities of topsoil removed ahead of the commencement of the roadbed treatment.
After completion of the roadbed treatment the Contractor, shall at no cost to the Employer, take cross-sections at a maximum spacing of 20 m so
as to determine the final roadbed levels and subsequently the quantities of any roadbed levelling operations, if any, ahead of the cut to fill
operations commencing.
The Engineer shall take control measurements to determine the accuracy and adequacy of the cross-sections, and shall instruct the Contractor
to correct any out of tolerance work and to take such additional measurements and cross-sections as may be deemed necessary. Such cross-
sections shall be taken before any cut or fill work is done.
Where the Contractor proceeds with further construction work before the Contractor and the Engineer have reached agreement on the accuracy
and adequacy of the cross-sections, the Engineer's decision regarding the cross-sections to be used shall be final and binding on the Contractor.
(vii) Material from commercial sources

Where specified in the Contract Documentation, material from commercial sources shall be used for the construction of roadbed treatment. In
such cases the items listed below shall be applicable, except that the tendered rates shall also include full compensation for all transport costs as
no load and haul shall be measured for commercial material.
(viii) Payment items specifically for this Section of the specifications
C5.1.1 Roadbed construction and compaction
C5.1.1.1 Compaction of in-situ material to 90 % of MDD cubic metre (m3)
C5.1.1.2 Compaction of in-situ material to 93 % of MDD cubic metre (m3)
C5.1.1.3 Compaction of imported material to 90 % of MDD cubic metre (m3)
C5.1.1.4 Compaction of imported material to 93 % of MDD cubic metre (m3)
C5.1.1.5 Compaction of in-situ sand roadbed to 95 % of MDD cubic metre (m3)
C5.1.1.6 Compaction of in-situ sand roadbed to 100 % of MDD cubic metre (m3)
The unit of measurement shall be the cubic metre of roadbed material prepared and compacted as specified. The quantity of the in-situ material
shall be computed in accordance with the authorised dimensions of the completed layers. The quantity of imported material shall be measured in
the haul vehicles, by taking the volume of the imported material to be the equivalent of 70 % of the loose volume in the haul vehicles.

The tendered rates for items C5.1.1.1, C5.1.1.2, C5.1.1.5 and C5.1.1.6 shall include full compensation for shaping, scarifying, mixing of in-situ
material and preparing and compacting the material to the specified MDD.
The tendered rates for items C5.1.1.3 and C5.1.1.4 shall include full compensation for shaping, scarifying with in-situ material where required and
mixing of the imported material or the in-situ/imported material blend, then preparing and compacting the material to the specified MDD.
The tendered rates for items C5.1.1.3 and C5.1.1.4 shall include for loading and off-loading the imported material. The haul of the imported
material shall be measured from the point of loading until the point of off-loading as per Section A1.7 of Chapter 1.
All material that requires being imported for the construction of the roadbed, to replace spoil material measured under item C5.1.2, or to replace
unsuitable material measured under C5.1.3, except the levelling layer which shall be paid under item C5.1.12, shall be measured and paid for
under this item C5.1.1.

C5.1.2 Excavate material to spoil sites designated by the Employer
C5.1.2.1 Excavate material to spoil from roadbed construction, material obtained from:
(a) Soft excavation cubic metre (m3)
(b) Boulder excavation Class A cubic metre (m3)
(c) Boulder excavation Class B cubic metre (m3)
(d) Hard excavation (other than by blasting) cubic metre (m3)
(e) Hard excavation (by blasting) cubic metre (m3)
C5.1.2.2 Excavate material to spoil from roadbed construction, using labour enhancement, material
obtained from:
(b) Intermediate excavation cubic metre (m3)
The unit of measurement shall be the cubic metre of material measured in its original position in cut and computed by the method of average end
areas from levelled cross-sections taken as specified.
Where measurement by cross-sections is considered by the Engineer to be impractical, cut to spoil may be measured in the haul vehicles, by
taking the in situ volume of the material to be the equivalent of 70 % of the loose volume in the haul vehicles.
For payment purposes a distinction shall be made between using conventional construction methods and using labour enhancement.
The tendered rates of item C5.1.2.1 shall include full compensation for excavating and loading from the road prism and roadbed the material in
the different classes of excavation. Haul shall be measured and paid for from the point of loading to the point of off-loading.
The tendered rates of item C5.1.2.2 shall include full compensation for using labour enhancement for excavating and loading from the road prism
and roadbed in the different classes of excavation. Haul shall be measured and paid for from the point of loading to the point of off-loading.
The excavation of hard material by blasting shall exclude the cost of blasting which shall be measured and paid for under item C12.10.1 in Section
C12.10 of Chapter 12.

C5.1.3 Excavate material to spoil sites designated by the Contractor
C5.1.3.1 Excavate material to spoil from roadbed construction, material obtained from:
(b) Boulder excavation Class A cubic metre (m3)
(c) Boulder excavation Class B cubic metre (m3)
(d) Hard excavation (other than by blasting) cubic metre (m3)
(e) Hard excavation (by blasting) cubic metre (m3)
C5.1.3.2 Excavate material to spoil from roadbed construction, using labour enhancement, material
obtained from:
(b) Intermediate excavation cubic metre (m3)
areas from levelled cross-sections taken as specified.
Where measurement by cross-sections is considered by the Engineer to be impractical, cut to spoil may be measured in the haul vehicles, by

taking the in situ volume of the material to be the equivalent of 70 % of the loose volume in the haul vehicles.
For payment purposes a distinction shall be made between using conventional construction methods and using labour enhancement.
The tendered rates of item C5.1.2.1 shall include full compensation for excavating and loading from the road prism and roadbed the material in
the different classes of excavation. All haul costs shall be included in the tendered rates for item C5.1.3..
The tendered rates of item C5.1.2.2 shall include full compensation for using labour enhancement for excavating and loading from the road prism
and roadbed in the different classes of excavation. All haul costs shall be included in the tendered rates for item C5.1.3..
The excavation of hard material by blasting shall exclude the cost of blasting which shall be measured and paid for under item C12.10.1 in Section
C12.10 of Chapter 12.
C5.1.4 Removal of unsuitable material to spoil
C5.1.4.1 In layer thicknesses of 200 mm and less
(a) Stable material cubic metre (m3)
(b) Unstable material cubic metre (m3)
C5.1.4.2 In layer thicknesses exceeding 200 mm
(a) Stable material cubic metre (m3)
(b) Unstable material cubic metre (m3)
The unit of measurement shall be the cubic metre of unsuitable material removed by the Contractor to spoil in accordance with the Engineer's
instructions, and it shall be the in-situ volume of the material calculated in accordance with the authorised dimensions. Where the use of authorised
dimensions proves to be unsatisfactory, then the unit of measurement shall be 70 % of the loose volume measured in the haul trucks.
The tendered rates shall include full compensation for excavating and loading the material from the road prism and roadbed in the different classes
of excavation.
Hauling shall be measured and paid for from the point of loading to the point of off-loading as per Section C1.7 of Chapter 1.
The removal of unsuitable stable material in cuttings is measured and paid for under item C4.2.7 of Chapter 4.
C5.1.5 In-situ treatment of roadbed in hard material
C5.1.5.1 In-situ treatment by ripping cubic metre (m3)
C5.1.5.2 In-situ treatment by drilling and blasting cubic metre (m3)
C5.1.5.3 In-situ treatment by drilling and splitting the material using non-explosive, rock-breaking cubic metre (m3)
products
The unit of measurement shall be the cubic metre of material treated in-situ as specified. The quantity shall be calculated from the authorised
dimensions of the in-situ treatment.
The tendered rates for items C5.1.5.1 and C5.1.5.2 shall include full compensation for ripping or for drilling and blasting, shaping, scarifying,
sizing, mixing of in-situ and imported material if required, processing and compacting the material as specified. Payment shall distinguish between
in-situ treatment by ripping only and in-situ treatment by drilling and blasting.
The excavation of hard material by blasting for item C5.1.5.2 shall exclude the cost of blasting which shall be measured and paid for under item
C12.10.1 in Section C12.10 of Chapter 12.
The tendered rates for item C5.1.5.3 shall include full compensation for drilling the holes, procurement of the rock-breaking product(s), charging
the drilled holes and splitting the material. The tendered rates shall also include for shaping, scarifying, sizing, mixing of in-situ and imported
material if required, processing and compacting the material as specified.
All imported material shall be measured and paid for under Section C5.2.
No separate payment shall be made for oversize or surplus material excavated to spoil as a result of this treatment.
Surplus material shall be measured and paid under item C5.1.1 if used in the roadbed.
C5.1.6 Roller-pass compaction
C5.1.6.1 Grid rollers square metre (m2)
C5.1.6.2 Pad foot vibratory rollers square metre (m2)
C5.1.6.3 Smooth drum vibratory rollers square metre (m2)

C5.1.6.4 Other vibratory rollers. Specify…… square metre (m2)
C5.1.6.5 Impact rollers square metre (m2)
C5.1.6.6 Pneumatic rollers square metre (m2)
C5.1.6.7 High energy impact compactor/roller (HEIC) square metre (m2)
C5.1.6.8 Other rollers. Specify….. square metre (m2)
The unit of measurement shall be the square metre of roadbed compacted in accordance with the specification for a single roller-pass. The
quantity will be measured in accordance with the authorised dimensions of the area to receive single roller-pass compaction.
The area to be roller-pass treated will be adjusted to be commensurate with the number of roller-pass treatments instructed. The authorised area
will be doubled when two roller-pass compaction is specified or trebled when three roller-pass compaction is specified in the Contract
Documentation, or instructed by the Engineer, and so forth.
The tendered rates shall include full compensation for shaping, providing the rollers, keeping the rollers operational and ready for when soil-
moisture conditions are favourable, and for compacting the roadbed with the specified number of roller-passes.
The Contractor shall base the tendered rates on a single, one direction pass for each specified type, size and weight of roller. The area covered
by the nominal roller overlap width required to ensure full coverage of the area being compacted shall not be measured for additional payment. If
the rollers available on site are different types, sizes and weights than those specified in the Contract Documentation, then revised rates which
take into account the percentage increased or reduced compaction effort per roller-pass, shall be agreed with the Contractor based on the same
percentage increase or decrease.
The unit of measurement for the addition of water shall be the kilolitre of water applied as required.
The tendered rates for the addition of water to achieve the required compaction shall include full compensation for the supply, delivery and
application of the water when required.
C5.1.7 Construction of a roadbed trial section
C5.1.7.1 Non wetting-up collapsing soil trial section at in-situ moisture content using conventional rollers cubic metre (m3)
and/or HEIC
C5.1.7.2 Non wetting-up collapsing soil trial section by excavating the soil to stockpile and then cubic metre (m3)
importing the soil from the stockpile to controlled compacted layers
C5.1.7.3 Wetting-up collapsing soil trial section cubic metre (m3)
C5.1.7.4 Inactive and normal clay
(a) By material modification cubic metre (m3)
(b) By lime modification cubic metre (m3)
(c) By removal of material cubic metre (m3)
C5.1.7.5 Active clay
(a) Roadbed construction using lime cubic metre (m3)
(b) Roadbed construction by removal of active clay cubic metre (m3)
C5.1.7.6 Roller-pass compaction. cubic metre (m3)

The unit of measurement for a trial section shall be the cubic metre of material processed during construction of the trial section according to the
authorised dimensions as specified in the Contract Documentation measured along the centre line of the road. A total length of at least 150 m of
trial section and no more than 200 m will be measured for payment as a trial section.
The authorised depth and width of the trial sections including item C5.1.7.1 (the depth of compaction) and item C5.1.7.3 (the depth of wetting-up)
shall be representative of what will ultimately be constructed as per the Contract Documentation.
The tendered rates for item C5.1.7.4(a) shall include full compensation to mechanically modify the material as specified in Clause A5.4.7.2 with
the type of material and ratios of material as specified in the Contract Documentation.
The tendered rates for item C5.1.7.4(c) shall include full compensation for excavating and loading from the road prism and roadbed the
inactive/normal clay material. Haul shall be measured and paid for from the point of loading to the point of off-loading.
The tendered rates shall include full compensation for setting out the trial section, preparing and providing the programme of work for the specific
trial section and preparing the existing roadbed surface where required.
The tendered rates shall include full compensation for the application of water, in the case of items C5.1.7.3, C5.1.7.4, C5.1.7.5 and C5.1.7.6, all
laboratory testing and for the full documentation of the construction techniques to produce a trial section that is compliant with the requirements
The addition of lime for construction of the trial sections shall be measured and paid for under Section C5.4.

C5.1.8 Construction of the roadbed in collapsing soil

C5.1.8.1 Non wetting-up collapsing soil roadbed construction at in-situ moisture content using cubic metre (m3)
conventional rollers
C5.1.8.2 Non wetting-up collapsing soil roadbed construction at in-situ moisture content using HEIC cubic metre (m3)
C5.1.8.3 Non wetting-up collapsing soil roadbed construction by excavating the soil to stockpile and cubic metre (m3)
then importing from the stockpile to controlled compacted layers
C5.1.8.4 Wetting-up collapsing soil roadbed construction kilo litre (kℓ)
C5.1.8.5 Water for wetting-up collapsing soil roadbed construction kilo-litre (kℓ)
The unit of measurement for items C5.1.8.1, C5.1.8.2, C5.1.8.3 and C5.1.8.4 shall be a cubic metre of collapsing soil material constructed
according to the authorised dimensions in the Contract Documentation, measured in-situ prior to the commencement of any construction.
The tendered rates shall include full compensation for setting out the collapsing soil material sections, for preparing and providing the construction
programme for the roadbed construction and preparing the existing roadbed surface where required.
The tendered rates shall include full compensation for construction of the roadbed treatment all in terms of the Contract Documentation and/or in
terms of the relevant compliant trial section constructed as per item C5.1.7. The tendered rates shall include full compensation for all labour,
construction plant including conventional rollers (C5.1.8.1) or HEIC (C5.1.8.2), equipment and incidentals required to carry out the construction of
the roadbed in collapsing soil material as specified.
The unit of measurement for item C5.1.8.4 shall be a kilolitre of water used to wet-up the collapsing soil.
The tendered rates for item C5.1.8.4 shall include full compensation for the provision and application of water for the construction of item C5.1.8.3,
applied as per the compliant trial section under item C5.1.7.3.
C5.1.9 Construction of roadbed comprising normal and inactive clay
C5.1.9.1 By material modification cubic metre (m3)
C5.1.9.2 By lime modification cubic metre (m3)
C5.1.9.3 By removal of material cubic metre (m3)
The unit of measurement shall be a cubic metre of inactive clay material constructed according to the authorised dimensions in the Contract
Documentation and down to a depth of 200 mm for both items C5.1.9.1 and C5.1.9.2.
The tendered rates shall include full compensation for setting out each inactive clay section and preparing the existing roadbed surface where
required. The tendered rates for C5.1.9.1 shall also include for loading the material.
The tendered rates for items C5.1.9.1 and C5.1.9.2 shall also include full compensation for construction of the roadbed treatment of inactive clay
by material modification or lime modification, respectively, as specified. The tendered rates for each item shall also include full compensation for
all labour, construction plant, equipment and incidentals required to carry out the construction of the roadbed by material modification or lime
modification as specified.
The hauling of compliant fill material shall be measured and paid for from the point of loading to the point of off-loading as per Section A1.7 of
Chapter 1.
The production of the compliant material is measured and paid for under Sections C4.1 and/or C4.2 of Chapter 4.
The procurement and mixing of the lime is specified and measured in Section A4.4 of Chapter 4 and Section C5.4 respectively.
C5.1.10 Construction of roadbed comprising active clay
C5.1.10.1 Roadbed construction using lime cubic metre (m3)
C5.1.10.2 Roadbed construction by removal of active clay cubic metre (m3)
The unit of measurement shall be a cubic metre of active clay material constructed according to the authorised dimensions in the Contract
Documentation.
The depth of treatment for item C5.1.10.1 shall be 200 mm unless otherwise instructed in the Contract Documentation or by the Engineer. The
depth of treatment for item C5.1.10.2 is the depth indicated in the Contract Documentation up to a limit of 750 mm unless instructed otherwise in
the Contract Documentation or by the Engineer.
The procurement and mixing of the lime for item C5.1.10.1 is specified and measured in Section A4.4 of Chapter 4 and Section C5.4 respectively.
The tendered rates shall include full compensation for setting out each active clay section and preparing the existing roadbed surface as specified.
The tendered rates for item C5.1.10.1 shall also include full compensation for construction of the roadbed treatment of active clay using lime
modification as specified.
The tendered rates for C5.1.10.2 shall also include for loading and off-loading the active clay. The hauling of the active clay material shall be

measured and paid for from the point of loading to the point of off-loading as per Section A1.7 of Chapter 1.
The tendered rates for each item shall also include full compensation for all labour, construction plant, equipment and incidentals required to carry
out the construction of the roadbed as specified.
C5.1.11 Construction of roadbed comprising a pioneer layer cubic metre (m3)
The unit of measurement shall be a cubic metre of pioneer layer material constructed in the authorised areas specified in the Contract
Documentation or as instructed by the Engineer.
The compacted volume of the pioneer layer of material shall be taken as equal to 70 % of the loose volume of material in the hauling vehicles.
The tendered rate for the construction of the roadbed treatment using a pioneer layer over water-logged or soft clayey ground as per the Contract
Documentation shall include full compensation for all labour, construction plant, equipment and incidentals required to carry out the construction
of the roadbed using a pioneer layer as specified.
The loading and hauling of compliant pioneer material for the roadbed construction is measured and paid for as specified in Section A1.7 of
Chapter 1.
The production of the compliant pioneer material is measured and paid for under Sections C4.1 and/or C4.2 of Chapter 4.
C5.1.12 Excavation for benches
C5.1.12.1 Excavation for benches
(a) Side-cut to fill in soft material cubic metre (m3)
(b) Side-cut to spoil in soft material cubic metre (m3)
C5.1.12.2 Excavation for benches using labour enhancement
(a) Side-cut to fill
(i) Soft material cubic metre (m3)
(ii) Intermediate material cubic metre (m3)
(b) Side-cut to spoil
(i) Soft material cubic metre (m3)
(ii) Intermediate material cubic metre (m3)
areas from levelled cross-sections taken as specified. The cross-sections shall be taken prior to excavating the cut for the benches.
Excavations shall be done using conventional construction and/or labour enhancement as specified and measured.
The tendered rates for excavating of benches under item C5.1.12.1 shall include full compensation for excavating from the road prism and roadbed
in the class of excavation indicated. The rate shall also include full compensation for moving, by bull-dozer or excavating and loading the fill
material a maximum of 1,0 km into its final location in the fill or for excavation, loading, off-loading and disposing of the spoil material at designated
spoil sites up to a maximum of 1.0km, as instructed by the Engineer, including shaping and levelling-off any piles of spoil material.
The tendered rates for excavating of benches under item C5.1.12.2 using labour enhancement, shall include full compensation for excavating
from the road prism and roadbed in the class of excavation indicated, loading the fill material, off-loading and disposing of the spoil material at
designated spoil sites, as instructed by the Engineer, including shaping and levelling-off any piles of spoil material. The tendered rates shall
include wheelbarrow transport over a haul distance of 100 m.
Hauling beyond 1,0 km when using conventional construction plant and 100 m using labour enhancement, shall be measured and paid for under
Section C1.7 of Chapter 1.
Construction of the fill is measured and paid for under Section C5.2.
Construction of the cut, exposed benched area, shall be measured and paid under the appropriate item in Section C5.1.
For payment purposes a distinction shall be made between materials as classified above.
C5.1.13 Construction of a levelling layer
C5.1.13.1 Over roadbed treatment in hard material compacted to 90 % MDD cubic metre (m3)
C5.1.13.2 Over a constructed pioneer layer compacted to 90 % MDD cubic metre (m3)
The unit of measurement shall be the cubic metre of material measured in its final position and computed by the method of average end areas
from levelled cross-sections taken as specified. The cross-sections shall be taken prior to the importation of the levelling layer and after completion
of the levelling layer.
When measurement by cross-sections is considered impractical the Contract Documentation may specify that the volume of the levelling layer

can be computed as 70 % of the loose volume in the haul trucks.
The tendered rates shall include full compensation for the construction of the levelling layer of varying thickness, with an average thickness of 200
mm and shall also include for all labour, construction plant, equipment and incidentals required to carry out the construction of the roadbed using
a levelling layer as specified as well as compaction to the specified MDD.
The production of the compliant levelling layer material is measured and paid for under Sections C4.1 and/or C4.2 of Chapter 4.
Loading and hauling of the compliant material for the levelling layer is measured and paid for in Section C1.7 of Chapter 1 and is measured from
the point of loading to the point of off-loading as per Section A1.7 of Chapter 1.

D5.1 ROADBED
CONTENTS
D5.1.1 SCOPE
D5.1.2 GENERAL

5.2 FILL
CONTENTS
A5.2.1 SCOPE
A5.2.2 DEFINITIONS
A5.2.3 GENERAL
A5.2.5 MATERIALS
A5.2.8 WORKMANSHIP

A5.2 FILL
A5.2.1 SCOPE
This Section covers the work requirements for off-loading and the subsequent processing of compliant fill material.
The work requirement for loading and hauling the fill material is specified in Section A1.7 of Chapter 1.
The fill material is produced as specified in the relevant Sections of Chapter 4.
A5.2.2 DEFINITIONS
The relevant definitions in the standard specifications are applicable. Additional definitions for this Section are included here.
Haul material - any construction material that is hauled between the point of loading, or the point of collection and the point of off-loading.
Construction material may include all borrow, cut and reclaimed materials produced as specified in Sections A4.1, A4.2 and A4.3 of Chapter 4
and all spoil, and unsuitable material. Material obtained from commercial sources or from alternative sources, as specified in Sections A4.4 and
A4.5 of Chapter 4, shall not be classified as haul material.
A5.2.3 GENERAL
A5.2.3.1 Fill dimensions and shape
The dimensions of fills shall be in accordance with the road design reflected in the typical cross-sections and other details contained in the Contract
Documentation.
The Contract Documentation shall contain relevant details regarding the following:
• the required slope/batter of each fill,
• geometric layout details of each fill at interchanges and intersections,
• the proposed use of material for each fill,
• the method and classification of compaction for the fills as per Clause A5.2.3.4.
• any physical restrictions or material conditions that may affect the construction of the fill, and
• the proposed sequence of fill construction along the length of the project.
During compaction, the fill layer shall be maintained to the required shape and cross-section.
The compacted fill layers shall be adequately drained and shaped to prevent water from standing on the fill layers or scouring the completed work.
A5.2.3.2 Fill adjacent to existing fill

Where existing fills are widened, or where new fills are to be constructed adjacent to existing fills such as to construct an additional carriageway
along with a median, the existing fill side slopes shall be benched in accordance with the details provided in the Contract Documentation.

A5.2.3.3 Fill layer thickness
The layer thickness used for the construction of the fills is dictated by the type and grading of the fill material and the compaction equipment being
used. Fill layer thicknesses specified in the Contract Documentation are based on the expected material type and on the use of typical compaction
equipment.
Fill layers shall be placed in successive layers at the same slopes and cross-fall as the final road surface. The construction of wedge-shaped fill
layers shall be restricted to the bottom layers of high fills where this may be unavoidable due to changes in the road cross fall and super elevation
or where the tapering out of the fill occurs. Benching shall be carried in terms of the specification in Clause A5.2.7.3 to avoid wedge-shaped fill
layers. Where a new fill layer is constructed on an existing or already constructed fill and the new layer will be less than 100 mm in compacted
thickness, the existing fill shall be scarified to such a depth as will give a compacted layer thickness of not less than 150 mm of the new plus
scarified material together.
During the initial construction of fill layers or of a trial fill section, if so instructed by the Engineer, the Contractor shall confirm the construction
layer thicknesses and the type of compaction equipment to be employed and shall then submit the method of compaction to the Engineer for
review and acceptance.
The compacted fill thickness shall be as follows for the different types of compliant fill material used unless specified otherwise in the Contract
Documentation or instructed by the Engineer after reviewing the Contractor’s compaction process and equipment.
a) Sand
Sand fill material may be compacted in layer thicknesses not exceeding 400 mm subject to the construction of a compliant trial section. The trial
section shall be constructed as part of the fill, at no additional cost to the Employer other than the cost of the actual constructed fill.
b) Normal fill
Normal fill material shall be compacted in layers not exceeding 200 mm after compaction.
c) Coarse fill
Coarse fill shall be compacted in layers not exceeding 500 mm after compaction.
d) Rock fill
The maximum compacted thickness of a rock fill layer shall not exceed 750 mm.
A5.2.3.4 Fill compaction classification

The classification of material as hard material or intermediate material in the case of labour enhancement, to compensate the Contractor for the
cost of excavation thereof, shall not be taken into consideration for any additional compensation in respect of the classification of the same material
when used in the compacted fill.
The method of processing and compacting the fill material shall be classified as specified hereafter.
a) MDD compaction
Wherever a density requirement in respect of a fill layer is specified in the Contract Documentation in terms of a percentage of MDD, the Contractor
may employ any type of compaction equipment to achieve such density over the full, as-specified, depth of the layer. The compaction equipment
employed shall be adequate and suitable for the purpose and shall not create lamination layers or shear cracks.
The Contractor shall restrict the size of the compaction equipment being used, if necessary, in order to ensure that no part of the already completed
works, any underlying structures, adjacent buildings or underground services are damaged during the compaction process.
(i) Sand fill
Sand fill material with properties as specified in Clause A4.1.5.4 of Chapter 4 shall be subject to a minimum percentage
compaction of MDD. This sand shall be compacted to 100 % of MDD, unless specified otherwise in the Contract Documentation.
Notwithstanding this compaction criteria, the compactability of the sand fill material shall be assessed and then confirmed by
means of the construction of an appropriate trial section or trial sections. The Contractor’s selected compaction process shall form
part of the submitted Management and Utilisation (M&U) plan.
(ii) Normal fill and coarse fill
Normal fill and coarse fill material shall both be subject to a minimum percentage compaction of MDD. The compaction density
shall normally be either 90 % of MDD or 93 % of MDD as specified in the Contract Documentation.
(iii) Fill widening
Unless specified otherwise in the Contract Documentation the fill material placed in a fill widening shall be benched as specified
in Clause A5.2.7.3 and compacted to 93 % MDD irrespective of the depth of the embankment fill, to avoid or minimise differential
settlement.
Where it is not possible to achieve 93 % MDD at the roadbed level, the Engineer shall instruct alternative roadbed compaction or
treatment.
(iv) Roller-pass compaction
When the bottom layer of a fill is compacted on top of soft or marshy ground, over a synthetic fibre membrane, the compaction
shall be carried out by roller-pass compaction in accordance with Section A5.1.
When the nature of the fill material is such that the degree of compaction cannot be satisfactorily controlled by testing the
compaction density, such as for a coarse fill or for a rock-fill, the compaction shall be carried out by roller-pass compaction in
accordance with Section A5.1.
The number of roller-passes, the combination of compaction equipment required and the fill layer thickness shall be confirmed by
means of the construction of a trial section in each case.
A5.2.3.5 Fill in restricted areas

Suitable equipment and acceptable methods shall be employed in restricted areas so that the required densities will be obtained throughout the

thickness of any one fill layer. If necessary, the layers shall be placed in thicknesses which are less than the specified layer thickness to suit the
type of compaction equipment being used in a restricted area.
Clauses A1.1.3.2 and A1.2.3.23 of Chapter 1 are applicable to all construction work in restricted areas.
A5.2.3.6 Contractor prepared plans for fills

The Contractor shall prepare and submit a Management and Utilisation (M&U) plan for every fill where the quantity of fill material exceeds 10 000
m3 or the length of fill exceeds 1,0 km.
To ensure that fill is constructed in a sustainable and sensitive manner, that environmental impacts are minimised, that fill layer material and
haulage thereof is optimised and that costs are minimised, the M&U plan for the fill shall at least take cognizance of the following and provide
detail of the following as appropriate:
• A method statement and programme for the construction of each fill
• A method statement for ensuring the material can be used directly to eliminate or minimise any temporary stockpiling;
• The sequence and processing of the fill directly from borrow, from cut or from stockpile;
• The survey methods to stake the toe of the fill embankments and control the side slopes and fill levels;
• A method statement of how the fill material will be protected from becoming too wet from whatever source of water;
• Details of any additional temporary drains that may be required along with the size, location and timing of the construction thereof, to protect
the road prism from storm damage during construction;
• How oversize material will be dealt with;
• How work will be carried out in restricted areas;
• A method statement of how benching for the widening of fills or for the construction of fills located on a steep cross-fall, will be carried out;
• Measures to comply with the conditions of the statutory road environmental approval;
• Measures to comply with regulations and obligations in terms of Section A1.2 of Chapter 1 and the current Construction Regulations;
• The quality assurance detail for the applicable materials tests along with the frequency and quantity of such testing for each constructed
section of each fill layer to ensure full compliance of the as-constructed fill in terms of compaction density and material quality, and
• Procedures for regular monitoring, auditing and reporting
M&U plans need to be submitted during the course of construction. The Contractor’s construction programme shall set out by when each M&U
plan will be submitted for review. The construction of a particular layer shall only commence once the Contractor’s M-&U plan for that layer has
been reviewed and accepted by the Engineer. The Engineer shall respond within one week after receiving an M&U plan.
A5.2.4 DESIGN BY THE CONTRACTOR/PERFORMANCE BASED SYSTEMS

A5.2.5 MATERIALS
A5.2.5.1 Material specification
The material specifications for use in the construction of fills are given in Section A4.1 of Chapter 4 in the following clauses:
• Clause A 4.1.2 Definitions for Sand fill, Normal fill, Coarse fill and Rock fill material under sub-heading Fill layers
• Clause A4.1.5.4 Sand, normal and coarse fill material in the earthworks
• Clause A4.1.5.5 Rock fill material in the earthworks layers
• Clause A4.1.5.9 Sand in fill and pavement layers of sealed low volume roads
• Clause A4.1.5.13 Drainage layer material
Material excavated for the construction of infrastructure such as open drains, subsoil drains, culverts, bridge foundations and other structures,
shall, if compliant and instructed by the Engineer, be used for the construction of fills.
A5.2.5.2 Use of fill material

The different types of fill material that can be used as fill material are defined in Clause A4.1.2 of Chapter 4.The specific use of each type of fill
material is specified hereafter:
• Only normal fill material shall be used at a depth less than 150 mm below the top of the fill, unless specified otherwise.
• Only normal fill or coarse fill shall be used to construct a fill widening unless specified otherwise.
• Coarse fill material shall only be used up to a depth of 150 mm below the top of fill, unless specified otherwise.
• Rock fill material shall only be used up to a depth of 300 mm below the top of fill, unless specified otherwise.
• The fill material to be used in high fills as per Clause A5.2.7.9 shall be specified in the Contract Documentation.
A5.2.5.3 Unsuitable fill material

When the Contractor renders compliant fill material unsuitable for use due to inappropriate handling and/or processing methods, then such material
shall be removed from the road and disposed of at a designated spoil site at no cost to the Employer. The replacement of the non-compliant fill

material shall also be at no cost to the Employer.
Where there is a nett surplus of cut material for use as fill, the Contractor may be reimbursed for the removal to spoil of the now non-compliant
material as if taken directly from the cut. A surplus of cut material for fill implies that the surplus has to be disposed of in any event. The Contractor
shall not be reimbursed for any costs for the replacement of the material, irrespective of the source of the replacement material.
All unsuitable fill material, whether designated unsuitable in the Contract Documentation or rendered unsuitable by the Contractor, must be broken
down sufficiently for convenient loading and transporting to the designated spoil area. Sufficient material shall be broken down to a maximum size
of 500 mm with a view to effectively trimming the designated spoil areas.
A5.2.5.4 Wet fill material

The Contractor shall take measures to prevent fill material on the road becoming excessively wet as a result of rain, groundwater or storm run-off
water. These measures shall form part of the Management and Utilisation (M&U) plan.
When these measures to keep the material dry and/or to dry it out have been taken and it remains too wet, the Engineer shall declare the material
to be unsuitable. If the material declared unsuitable has already been placed on the road, the Engineer shall instruct that it be removed and
replaced with alternative compliant material at no cost to the Employer.

Construction equipment to carry out the construction of fill efficiently shall comply with the requirements of Clause A1.2.6 of Chapter 1.

A5.2.7.1 Compaction of fill material
Material used for the construction of a fill layer, from borrowpits or from cuttings, shall be prepared and used as set out in Clauses A4.1.7 and
A4.2.7 of Chapter 4 respectively, during the excavation, placement and compaction thereof.
After fill material in borrow pits and cuttings has been broken down to the maximum size specified in Clauses A4.1.7 and A4.2.7 of Chapter 4 and
then spread on the road, the oversize in excess of 5 % by volume shall be further broken down by means of suitable equipment such as a grid roller
or a pad-foot roller.
In many cases breaking down oversize material by the normal compaction process may prove adequate, and no special effort should be necessary
for breaking down the material, but, in the case of hard material, the engineer may require that the material be broken down by light grid-rolling. The
degree to which the breaking down occurs shall then serve as the norm for what may be required with regard to alternative breaking down methods.
For the purposes of these specifications light grid-rolling is defined as follows:
• The material shall be spread in a layer, the uncompacted thickness of which shall be approximately the average maximum fragment size, but
with a minimum uncompacted thickness of 200 mm. It shall then be rolled by means of at least two complete roller-passes per 200 mm
uncompacted layer thickness, by a grid roller with a mass of not less than 13,5 tons, travelling at a speed of at least 12 km/h whether towed or
self-propelled. Should the uncompacted layer thickness be in excess of 200 mm, the roller-passes shall be increased pro rata.
Compensation for the light grid-rolling process to break down oversize material shall be regarded as being included in the pay item for providing,
processing and compacting the material. Even when fill material is instructed to be compacted by means of a certain number of roller-passes, the two
passes for breaking down the material will not be measured for payment.
Material that contains in excess of 5 % by volume of oversize material shall not be hauled to the road for use in sidewalks and in shoulder widenings.
Where any fill material contains less than 5 % by volume of oversize material, the oversize material shall be broken down by means of appropriate
compaction equipment such as a grid roller or a pad-foot roller, or shall be bladed out of the layer or be removed from the layer by hand.
Compaction shall be carried out in a series of continuous operations covering the full width of the layer concerned. The length of any section of a
layer being compacted shall normally not be less than 150 m nor more than what can be properly compacted during the available working period
with the available equipment. The Contractor shall reduce the length of any fill layer compacted in any single operation if the specified compaction
of such a layer is not being achieved.
The types and/or combination of compaction equipment to be used and the amount of rolling to be done shall be such as to ensure that specified
densities or the required number of roller-passes are obtained without damage being done to the lower fill layers or underlying structures.
All holes, depressions or ruts shall be filled with compacted material and any lamination layers that may develop in the layer shall be removed or
processed again to a minimum compacted depth of 150 mm.
A5.2.7.2 Fill drainage and protection

a) Road prism drainage
During fill construction, the road prism shall be kept well-drained and protected at all times by the Contractor.
The Contractor shall construct all permanent drains as soon as possible, as well as sufficient additional temporary drains as may be necessary to
protect the road prism.
The provision of temporary drainage works shall include providing open channels, cut-off banks and the provision of and operation of temporary
pumps and such other equipment as may be necessary for adequately protecting, draining and dewatering the works and the temporary works.
This temporary provision will be in addition to any permanent drainage works specified and installed, and in addition to any temporary drainage
works specifically paid for separately as in the case of diversions.
Throughout the construction of the works these permanent and temporary drainage provisions shall be maintained in good working order.
b) Fill layers drainage
Material spread over the road shall be spread with a cross slope at or greater than the slope of the final road surface and, if not directly compacted,
it shall receive at least one complete roller-pass compaction with a flat-wheel roller in order to allow the water to run off rather than penetrate the
uncompacted spread material. Precautions shall be taken to ensure that water does not dam up against material heaps, windrows, or any spread

material or collect in low spots where it can form a pond and soak into the completed fill material.
Where fill material, despite proper precautionary measures, on account of its in-situ moisture content, is too wet to comply with the requirements
with regard to moisture content during compaction, the Contractor shall dry out the material until it is suitable for compaction. Where wet in-situ
conditions exist the Contractor shall, where possible, plan the construction programme so that material with a high natural moisture content will
be excavated, placed and compacted during the dry season and not in the wet season.
The Contractor shall decide on the best method to dry wet material.
c) Fill protection
All completed fill layer work shall be protected and maintained until the following layer is constructed. Maintenance shall include immediate repairs
to any damage or defects which may occur and shall be repeated as often as may be necessary to keep the layer continuously intact and in a
good condition.
Ruts and potholes developing in the fills after completion shall be repaired, and damaged portions of the fills shall be reshaped and re-compacted
at no cost to the Employer. Material shall not be spread on a constructed fill layer that is above its optimum compaction moisture content which can
result in damage being caused to the layer during compaction of a subsequent layer.
All windrows shall be cut away or removed immediately after construction work to prevent the concentrated flow of water on completed fill layers.
Cut-off berms or banks shall be constructed when and where required to prevent the erosion of fill slopes.
All cut and fill slopes shall be maintained by the Contractor until the road has been certified as being finally completed. All erosion and flood
damage to slopes shall be promptly repaired.
Side drains discharging water from cuts and all other drains shall be so constructed as to avoid damage to the fills by erosion during the period
before completion of the construction of the final drainage design.
A5.2.7.3 Benching for fill construction

Where the natural cross fall of the treated roadbed exceeds 1 vertical to 10 horizontal (1:10), the new fill shall be bonded to the roadbed by
construction of benches.
The dimensions of the benches shall be as detailed in the Contract Documentation. The excavated material to create the benches shall be used
directly for the construction of fill or taken to spoil as per the details in the Contract Documentation or as instructed by the Engineer.
The depth and width of benches cut into hard material may normally be smaller than those in soft material. Where benches are cut into hard
material, the toe of the fill shall preferably also be constructed from rock material, and the benches shall be at least as deep as the largest rocks
or boulders in the fill material. Benches in hard material shall be excavated to slope slightly inwards and the benched floor must have a broken
and roughened or serrated surface so as to obtain a good bond between the surface of the bench and the fill material compacted on top of it.
The benches may be constructed in accord with Method A or Method B. The benching per Method A does not extend beyond the extremity of the
road prism. The benching per Method B extends beyond the extremity of the road prism. All suitable and excess material obtained from the
excavations for benching shall, in so far as is possible, be re-used for constructing the fills.
a) Method A
This method requires the cut of the first bench in the roadbed to be of adequate width to accommodate normal-width self-propelled construction
equipment. The widths of successive benches shall be determined by the width of the fill at the elevation of the next bench.
The width of benches shall decrease gradually up to the stage where the fills in any case are wide enough for accommodating normal-width self-
propelled construction equipment.
b) Method B
This method does not require the benching at the toe of the fill to be cut back adequately for accommodating normal-width construction equipment.
The bench width shall be less than the normal-width for construction equipment and requires the fills then constructed to be so much wider (beyond
the toe of the fill) as may be necessary for accommodating such equipment up to the height where the fill is sufficiently wide for construction
equipment.
The Contract Documentation shall detail the width of the lowest bench to be cut beneath the new fill and the entire benching detail.
The position of the narrow first bench at the toe of the fill shall be accurately set out.
In the case of Method B benching construction, the Engineer may instruct that any excess width constructed adjacent to the toe of the fill should
be removed to fill.
A5.2.7.4 Widening of fills

Where existing fills are to be widened, the fill slopes and the roadbed onto which the new fills are to be constructed shall be cleared and grubbed,
as detailed in the Contract Documentation.
Where existing fills, or fills already constructed under the current project, are required to be widened or flattened, it shall be done by way of bench
construction in accord with Clause A5.2.7.3 and as per the details in the Contract Documentation. The Contractor shall submit proposals for each
fill widening or fill flattening less than 10 000 m3 not already included in the M&U plan, to the Engineer, for review before proceeding with such work.
Benches of not more than 500 mm vertical depth shall be cut into an existing fill. In the case of fills of less than 1,0 m height, and in the upper
metre of any fill, the benches shall have a vertical depth equal to the actual individual fill layer thickness specified for constructing the widening.
When the side slope of the existing fill contains any uncompacted material, the benches shall extend ‘sideways’ in a horizontal plane for a distance
of at least 1m into the properly compacted portion of the original fill material or as per the details specified in the Contract Documentation.
All suitable material derived from cutting the benches shall be used in the construction of the widened section of the fill. Unsuitable material shall
be removed to a designated spoil site as instructed by the Engineer or as per the Contract Documentation. Benches shall be compacted at the
same time as the fill widening during the construction of the fill.
Where the existing fill consists of normal fill or coarse fill the widened section shall consist of normal fill or coarse fill respectively unless specified
differently in the Contract Documentation.
A5.2.7.5 Rock fill embankment toe

Where required, rock fill embankments shall be protected by special embankment-toes, which shall be installed as detailed in the Contract

The toe shall be constructed simultaneously with the rest of the rock fill and shall consist of rock fill material varying in size between 150 mm and
the maximum size of 500 mm. Where detailed in the Contract Documentation, a layer of synthetic-fibre filter material and a sand blanket shall be
installed at the interface between the embankment rock fill and the rock fill protection toe. Care shall be taken not to damage or tear such material.
The toe shall be constructed and compacted as specified for rock fill. The outer part of the toe shall consist of the larger rocks properly bedded by
means of smaller fragments so as to form a stable interlocking surface.
If placing with mechanical construction equipment does not achieve the required results, the equipment shall be supplemented with manual labour
to select, to lever and place keystones in between the larger boulders until the correct placing is achieved and the rocks are firmly interlocked.
A5.2.7.6 Construction of rock fill

If the compacted layer is less than 500 mm thick then the largest dimension of any rock fragment shall not exceed the thickness of the compacted
layer.
The material to be compacted shall be off-loaded by the end-tipping method. The material shall then be spread by bulldozer or other suitable
equipment and shall be so bulldozed and levelled as to properly mix the fine material with the rock. The routes to be followed by hauling, spreading
and compaction equipment shall be uniformly distributed over the entire width of the layer to be compacted. The material shall be compacted
during the spreading and compacting process using suitable rollers and finally compacted with vibratory rollers to achieve a good mechanical
interlock of the rock and the best possible compaction and interlock of the finer material in the spaces between the rock.
The type of vibratory roller used, the operating speed, the number of passes and the layer thicknesses are determined by means of the following
formula:
(Pe × n) ∕ (h × v) ≥ 1500
Pe = total static and dynamic force per metre width generated by the vibratory roller at the operating frequency given by the
manufacturer (kN/m)
n = number of passes required
h = thickness of the compacted layer in metres
v = roller speed in metres per second.
Operating frequencies shall be between 18 Hz and 30 Hz and Pe shall be at least 120 kN/m.
The rock fill shall contain sufficient fine material to fill the voids between the rock particles to form a dense layer with minimum voids between the
rocks.
Rock fill that does not have sufficient fine material to fill the voids can be used in the works. After placing this rock fill, sandy material as specified
in Clause A4.1.5.5 of Chapter 4 shall be spread uniformly over the surface using stiff brooms and the dry or watered sandy material shall then be
rolled with a smooth drum vibratory roller and worked into the rock fill until no further settlement of the finer material occurs between the rocks and
that all areas deficient in fines have been corrected.
The process shall continue until the voids in the rock fill have been adequately filled. All excess fines shall be removed from the surface of the
rock fill. If the voids in the rock fill cannot be properly filled the thickness of the rock fill layers must be reduced so that it is possible to fill the voids
to the bottom of each of the rock fill layers.
At the commencement of construction of a rock fill a trial section shall be constructed so that the rock fill construction process can be checked,
amended if necessary and agreed to by the Engineer.
A5.2.7.7 Protection of structures

Proper precautionary measures shall be taken and, where necessary, additional temporary protection and/or support measures shall be provided
to ensure that the method or procedure by which the fills are constructed will not impose excessive loads on the structures, especially on
incomplete structures, as this may damage or overstress such structures.
A5.2.7.8 Fills up to 10 m high

Before the normal or coarse fill material is compacted, it shall first be thoroughly mixed by grader or other suitable equipment so as to obtain an
even mix of the material and to spread the fine and coarse material evenly throughout the mixture. If necessary during the mixing process, water
shall also be sprayed evenly over and mixed into the material to bring it to the correct uniform moisture content.
The moisture content to which the material shall be brought by adding water shall be sufficient to bring the material to the most favourable moisture
content for the specific compaction equipment to be used and the percentage compaction required. If the moisture content of the material is in
excess of 2 % above the optimum moisture content for the MDD, the Contractor shall still ensure the required compaction is obtained by carefully
monitoring and adjusting the compaction technique or the material shall first be dried out to the required moisture content before compaction
commences
A5.2.7.9 Fills higher than 10 m

The construction of high fills shall require special techniques to prevent the development of excessive pore pressure and ensure the stability of
such fills during and after construction.
These techniques may include, inter alia, the selection of better class material for use in the bottom layers of the fill, the construction of drainage
blanket layer/s and the strict control of moisture content during compaction.
Permanent benches or steps shall be constructed in the batters or slopes of fills higher than 10 m for future access and maintenance purposes.
These benches shall be sloped gently back towards the fill batter and catch water drains must be constructed on the benches to intercept storm
water runoff. The width and slope of these benches shall be as detailed in the Contract Documentation.
The material requirements for the construction of fills higher than 10 m are set out in Table A4.1.5-2 in Section A4.1 of Chapter 4. The specific
requirements for the construction works shall be implemented as detailed in the Contract Documentation.
A5.2.7.10 Drainage layer(s) in fills

At the bottom of fills, and sometimes at intermediate levels, the construction of a drainage layer or a sand filter layer or other specified drainage

layer may be required to facilitate the drainage of fills. The requirements for the installation of a drainage layer shall be specified in the Contract
Documentation. The grading of the material used for the drainage layer shall be as per Table A4.1.5-13 of Chapter 4.
Sand filter blankets shall be constructed in accordance with the details in the Contract Documentation. The surface on which the sand filter blanket
is to be constructed, shall be smooth and even and the sand shall be spread evenly to the required thickness and be given a one roller-pass
compaction with a suitable roller. The final surface of the sand filter blanket shall be finished off true to line and level.
If the fill material consists of coarse material with a maximum particle size exceeding 75 mm the layers immediately below and above the filter
blanket shall be constructed from selected soil or gravel with a maximum particle size of 50 mm.
A5.2.7.11 Drainage layer(s) in cuttings

Once the roadbed preparation through a cutting with a hard formation has been constructed in accordance with the details in the Contract
Documentation, the initial layer on top of the completed roadbed shall be a drainage blanket layer where specified in the Contract Documentation.
The drainage blanket layer shall be constructed on top of the roadbed with material which conforms to the requirements for a drainage blanket
layer as specified in Section A4.1 of Chapter 4 and shall merely be lightly compacted with an agreed number of roller-passes to smooth and level
it.
The drainage blanket layer shall have a nominal placement thickness of 150 mm with a minimum compacted thickness of not less than 100 mm
in any one place, and shall comply with the level tolerances for the equivalent fill or pavement layer. The average drainage layer thickness based
on levels before and after placement of the drainage layer shall not exceed 200 mm.
The drainage blanket layer shall be protected from contamination by installing suitable geotextile layers below the blanket layer and then on top
of the drainage layer ahead of the next layer of fill or of the pavement. The compacted thickness of the next layer of material constructed on top
of the drainage layer shall have a maximum compacted thickness of 200 mm and only the upper 150 mm of the layer shall be processed and
compacted. The density shall be as specified or the layer shall be compacted by approved roller-pass compaction all as instructed by the Engineer.
This will ensure that neither the geotextile over the drainage layer or the drainage layer itself will be compromised.
A5.2.7.12 Fill in restricted areas

Clauses A1.1.3.2 and A1.2.3.23 of Chapter 1 are applicable to all construction work in restricted areas.
a) Additional requirements
In restricted areas the Engineer may permit the Contractor to spread, water and mix the fill material in a windrow next to the working area or at a
nearby location from which it can be loaded and hauled to the working area. Care shall be taken not to damage any adjacent works and not to
contaminate the mixed material with deleterious material. Where this method of mixing is impractical or impossible, the Contractor shall make
use of concrete mixers or any other mixing equipment or acceptable method.
Irrespective of the layer concerned, the mixing shall ensure that a uniform mix will be obtained at all times. Areas where mixing of materials
probably could be done in this manner is for the construction of a sidewalk, a shoulder widening or any other area identified in the M&U plan.
b) Construction of fills near structures
At structures such as bridges and large culverts, the construction of the fill and the backfilling immediately adjacent to the structure cannot be
done simultaneously. The fills shall be so constructed that the longitudinal slope of the surface of the fill shall at all stages form a continuous plane
sloping at a gradient not exceeding a 10 % incline towards the original ground level at the structure or the changing ground level at the structure
as backfill progresses against the structure. Temporary drainage measures must be provided to ensure that rain water or storm water run-off,
does not form ponds at the structures.
When the structure is completed, the remaining portion of the fill shall be completed including benching into the 10 % slope, simultaneously with
the backfilling behind the structure.
The backfill behind and fill over the top of the structure, when applicable, shall be maintained at the same elevation as the benching of the adjoining
fill.
A5.2.7.13 Finishing off slopes

a) General requirements
The Contractor shall not disturb the slopes of cuts and fills of an existing road prism unless such cuts or fills are required to be widened or flattened.
Where the new road has been widened temporarily to accommodate traffic and the widening is no longer required, it shall be trimmed back to the
standard cross-section as per the Contract Documentation or as instructed by the Engineer. The surfacing shall be saw-cut or cut with a trimming
wheel. This forms a neat reference line along the new shoulder breakpoint and the surplus material shall then be bladed off to the required slope,
loaded and transported to a designated landfill site or other designated spoil area. The road surface shall not be damaged.
When so instructed by the Engineer, adjustment to the slopes shall be made to avoid damage being done to existing trees and to harmonise with
existing landscape features. The transition to such adjusted slopes shall be gradual.
Clause A1.2.3.23 of Chapter 1 is applicable for slopes in restricted areas requiring to be finished.
b) Fill slopes
The side slopes of fills shall be finished (or shaped) as follows:
• The slopes shall be finished to a standard which is generally obtainable with proper care and workmanship in the type of material concerned.
Care shall be taken not to undercut any side slopes which can cause sections to have a steeper slope than specified.
• Slopes at the junction of cuttings and fills shall be adjusted and evenly shaped so as to flow into one another or into the natural ground
without a noticeable break that can be readily discerned from the road,
• The degree of finish required shall depend on the nature of the material used for the construction of the fill and hence of the fill slope but
shall be as smooth as is consistent with the material involved and good workmanship.
• No individual boulders occurring in otherwise smaller sized material shall be allowed to project beyond the surface. All loose rocks, boulders
and cobbles in excess of 75 mm shall be removed from the finished side slopes,

• In the case of rock fill, soft material shall be dumped over the sides of fills and worked into the gaps or voids between the rock on the surface
of the fill slope.
• Slopes within soft material shall be finished to the natural angle of repose of the material or to a maximum slope of 1 vertical to 2 horisontal.
• The final surface of the side slopes shall have a slightly roughened surface that will be suitable for subsequent top soiling and grassing,
• Fill slopes shall be finished to neat lines with normal fill material. Any boulders or otherwise unsuitable material deposited on such slopes
from overspill or whatever other reason shall be removed and any damage caused shall be reinstated, including the re-establishment of
vegetation where applicable.
• Batters / fill slopes shall be finished to within a tolerance of 100 mm above to 100 mm below the specified side slope line. All undulations
shall follow a smooth line.
• The removal of over-built material on fill slopes shall be completed before any pavement layer work is commenced with, that is before the
pavement layer profile pegs are erected.
• The final finishing of fill side slopes, profiling and cleaning shall be completed after the completion of the construction of all the pavement
layers but before commencing with the placing of any surfacing.
• The tops (shoulder break point) and bottoms (edge of road prism) of all side slopes shall be rounded. The extent of this rounding shall be
600 mm, or as indicated on the drawings or as instructed by the Engineer,
• In preparation for grassing the side slopes designated for grassing shall receive a 75 mm to 150 mm thick topsoil layer as per Chapter 11 of
the specifications and shall be vegetated.
c) Median slopes and interchange areas
Median slopes and the areas between interchange ramps shall be finished to the same level tolerances as specified in Clause A5.2.8.3 for the
top layers of fills. This tolerance shall apply to the top layer of these slopes and areas.
For the sides of fills steeper than 1 in 4, the requirements of Clause A5.2.7.13b) shall apply.
d) Cutting slopes
The finishing of cutting slopes is specified in Clause A4.2.7.1n)
A5.2.7.14 Spoil of surplus and redundant fill material

Any surplus fill material such as waste or oversize material bladed off the road, shall be disposed of as spoil material by the Contractor as instructed
by the Engineer at a designated spoil site or at a landfill site. Spoil material shall not require compaction but shall be spread, shaped and given a
smooth surface as may normally be obtained by using a bulldozer.
Excess fill material placed by the Contractor outside the specified lines and levels shall be removed during the trimming operation at no cost to
the Employer and it will not be measured for payment as cut to spoil.
A5.2.8 WORKMANSHIP
The Engineer shall do specific inspections of completed layers prior to the next layer being imported and specifically to determine whether the
layer is still intact and after a rainfall to determine whether the layer has become saturated due to poor provision for temporary drainage.
A5.2.8.2 Material quality and compaction requirements

The quality of fill materials shall comply with the requirements of Chapter 4 prior to the material being transported to the site.
The compaction of fill materials shall comply with the requirements specified in Clause A5.2.3.4 and summarised in Table A5.2.8-1.
Table A5.2.8-1: Summary of material requirements and layer thickness
Material description or use Type of compaction Individual layer thickness (t) Compaction (% of MDD)
Sand Fill MDD t < 400 mm 100 % as per Clause A5.2.3.4
90 % or 93 % as per the Contract

Normal fill MDD t < 200 mm
documentation
90 % or 93 % as per the Contract

Coarse fill MDD t < 500 mm
Documentation
Rock fill Formula T < 750 mm Formula as per Clause A5.2.7.6
Fill widening (only normal or

MDD 200 mm < t < 500 mm 93 % for entire height of fill
coarse fill material to be used)
Fill over soft or marshy terrain

Determine number of roller-passes by trial
using compliant fill material as Roller-pass Determine by trial section
section
instructed by the Engineer
The in-situ measured density of the fill layer being tested complies with the compaction requirements when the results of at least 75 % of the in-
situ density tests of any lot, located as per the Contract Documentation, are equal to or exceed the specified value and no single density is more
than 3 percentage points below the specified value.

Fill materials treated by providing roller-pass compaction shall be compliant when the agreed number of passes as determined during the
construction of a trial section, or as specified in the Contract Documentation, or as instructed by the Engineer have been observed and recorded
as being the correct quantity.

The work specified in this Section shall be constructed to the following dimensional tolerances.
a) Levels
The level tolerances shall be as follows for fill, but shall apply only to the top layer of the fill:
H 90 = ± 25 mm
H max = ± 35 mm
b) Width
(i) Normal fill and coarse fill
The horizontal measurement taken from the centre line of the road to the side of the fill, shall nowhere be 125 mm less or 250 mm
more than the specified dimension when measured at any level.
(ii) Rock fill
The horizontal measurement taken from the centre line of the road to the side of the fill, shall nowhere be 250 mm less or 1 000
mm more than the specified dimension when measured at any elevation.
c) Fill batters or slopes
The construction tolerances specified in Clause A5.2.7.13b) shall be complied with.

B5.2 FILL
CONTENTS
B5.2.1 SCOPE
B5.2.2 DEFINITIONS
B5.2.3 GENERAL
B5.2.5 MATERIALS
B5.2.8 WORKMANSHIP
B5.2.1 SCOPE
This Section covers the work requirements for off-loading and the subsequent processing of compliant fill material. The work requirements for
loading and hauling the fill material is specified in Section A1.7 of Chapter 1.
This Section therefore includes work with a component of labour. This work is included in Part A of this specification. This Part therefore only
covers additional specifications for work to enhance the labour component of construction activities where specified.
B5.2.2 DEFINITIONS
B5.2.3 GENERAL
B5.2.4 DESIGN BY THE CONTRACTOR / PERFORMANCE BASED SYSTEMS

B5.2.5 MATERIALS


For this section, fill in sidewalks and road widenings are suitable components for labour enhancement.
B5.2.8 WORKMANSHIP

C5.2 FILL
(i) Preamble
constructional plant, equipment, labour, tools, incidentals and supervision to carry out the activity or construct the works in the item, unless
otherwise stated.
deemed appropriate:
1. Drainage and protection of the works from all damage that may occur for any reason until the Employer has taken over the works.
2. Protection and repair as required, until the Employer has taken over the works, of all existing and new roadside furniture, of all existing and
new drainage structures and of all existing and new infrastructure. Any other items adjacent to, over or under the road that could be damaged
by the Contractor’s vehicles, equipment, or by public traffic being accommodated on or alongside the works, during the construction of the
works.
3. Repair of any damage to the fill and services that may occur for any reason before, during or after the construction of the roadbed up until
the Employer has taken over the works.
4. Provision of material in excess of the compacted volume of the layers calculated using the layer dimensions given in the Contract
Documentation for whatever reason including additional material required for the correct placing, mixing, levelling and compaction of the
layers.
5. Removal of all excess material required for the correct mixing and working of the layers and left in windrow or on the sides of the road.
6. No additional payment will be made for keeping dry or for drying out the fill material. The cost of such work shall be included in the tender
rates for the various items of work for which the material is to be used, unless provision for additional compensation of this nature has been
made in the Contract Documentation.
7. Where the material contains more than 5 % oversize material breaking down the oversize material as per Clause A5.2.7.1 using two roller-
pass grid rolling.
8. Loading of the fill material during the excavation operation when the material is taken directly to the point of use.
9. Loading and hauling of commercial fill material identified by the Employer or by the Contractor.
10. Loading and hauling of alternative fill material identified by the Contractor.
For activities in Table C5.2-1 payment items specified in other Chapters of the specification, where they relate to work under this Section, will be
listed in the Pricing Schedule.
Drainage A5.2.7.2
applicable items
Hard material A5.2.7.3
applicable items
Ground improvement (Specialist roadbed treatment) A5.2.7.4
applicable items
Clearing and grubbing and removal of large trees A5.2.7.4
applicable items
Synthetic fibre filter A5.2.7.5
applicable items
Topsoiling A5.2.7.13.2
applicable items
Additional testing A5.2.1
applicable items
Loading and hauling material All A5.2 references
applicable items
(iv) Determining the quantities

The Contractor and the Engineer shall determine quantities for the work specified in this Section C5.2 all as specified in Section C5.1 under clause
C5.1(vi) Determining the quantities.
(v) Roadbed subsidence
Where it has been determined that the roadbed is subsiding as fills are being constructed, and after the roadbed work has been completed and

cross-sections have been agreed on, the Contractor may request that the fill quantities shall be adjusted accordingly. Such requests shall be
lodged without delay as soon as the Contractor becomes aware of any possible subsidence and the Contractor shall submit the required supporting
evidence to the Engineer. Where the Engineer is satisfied that significant subsidence is occurring, the Engineer and the Contractor shall decide
as to how the extent of the subsidence is to be determined. Any adjustments for subsidence shall be made only where the average subsidence
exceeds 50 mm.
The measurement and payment for the planned subsidence of a roadbed by means of pre-loading is specified in Chapter 12.
(vi) Work in restricted areas
Clause C1.1.3.2 of Chapter 1 shall be complied with.
(vii) Payment items specifically for this Section of the specifications
C5.2.1 Compiling and implementing M&U plans
C5.2.1.1 For fills more than 10 000 m3 (list all fills separately) number (No)
C5.2.1.2 For fills 1,0 km in length when less than 10 000 m3 (list all fills separately) number (No)
The unit of measurement shall be the number of compiled M&U plans for the construction of the fills.
The tendered rates shall include full compensation for gathering all information and compiling the plans and for ensuring the implementation of
the plans during the construction of each fill for which an M&U plan has been compiled.

C5.2.2 Fill construction
C5.2.2.1 Normal fill material in compacted layer thicknesses of 200 mm and less:
(a) Compacted to 90 % of MDD cubic metre (m3)
(b) Compacted to 93 % of MDD cubic metre (m3)
(c) Roller-pass compaction square metre (m2)
C5.2.2.2 Coarse fill material in compacted layer thicknesses exceeding 200 mm: but less than
500 mm
(a) Compacted to 90 % of MDD cubic metre (m3)
(b) Compacted to 93 % of MDD cubic metre (m3)
(c) Roller-pass compaction square metre (m2)
C5.2.2.3 Sand fill material in compacted layer thicknesses of 400 mm and less, compacted to 100 % of cubic metre (m3)
MDD
C5.2.2.4 Rock fill material all as per Clause A5.2.7.6 cubic metre (m3)
C5.2.2.5 Rock fill embankment toe cubic metre (m3)
C5.2.2.6 Sand filter layer cubic metre (m3)
C5.2.2.7 Drainage blanket layer cubic metre (m3)
The unit of measurement except for items C5.2.2.1(c) and C5.2.2.2(d) shall be the cubic metre of material measured in the compacted fill. The
measurement of fill shall distinguish between the different types of fill and methods of processing and compacting.
The unit of measurement for items C5.2.2.1(c) and C5.2.2.2(d) shall be the square metre of roadbed compacted in accordance with the
specification for roller-pass compaction.
The quantity measured for items C5.2.2.1(c) and C5.2.2.2(d) shall be in accordance with the authorised dimensions of the area to receive roller-
pass compaction as specified in Clause A5.1.7.3.
The quantity measured for items C5.2.2.1, C5.2.2.2, C5.2.2.3 and C5.2.2.4 except for items C5.2.2.1(c) and C5.2.2.2(d) shall be computed by the
method of average end areas from levelled cross-sections. The cross sections shall be prepared from the ground line after completion of clearing
and grubbing, after the removal of topsoil and after the completion of any roadbed treatment, but immediately prior to the construction of the fill.
The final specified or authorised fill cross-sections in the Contract Documentation shall be superimposed thereon at 20 m intervals along the
centre line of the road. All measurement shall be neat, and that part of the fill placed in excess of the authorised cross-sections, shall not be paid
for, irrespective of the tolerances in workmanship allowed under the contract.
Where the roadbed has subsided under the fills, the fill quantities shall be adjusted to make allowance for such subsidence, as set out in Clause
C5.2 (v).
The quantity measured for items C5.2.2.5, C5.2.2.6 and C5.2.2.7 shall be calculated from the authorised dimensions.
The tendered rates for all items shall include full compensation for preparing, processing, shaping, watering, mixing, and compacting the materials
to the densities or in the manner specified. The tendered rates shall also include for breaking down or removing and disposing of any oversize
material up to 5 % of the compacted volume from the road after processing, including loading and hauling the material to designated spoil sites.
The limit of 5 % shall apply to individual layers and not to all the layers together.

Loading of the fill material shall only be measured when the material is taken from stockpile, when approved by the Engineer. The haul of the fill
material shall be measured from the point of loading/collection to the point of off-loading as per Section A1.7 of Chapter 1.
The tendered rates for material excavated for the construction of other infrastructure as per A5.2.5.1 and used for the construction of fills, shall
also include for loading and off-loading the material. This is irrespective of any payment made for the excavation of such material. Payment shall
be made under the appropriate item in C5.2.2.
C5.2.3 Side-cut to fill compacted to 93 % of MDD in compacted layer thicknesses of 200 mm cubic metre (m3)
and less
The unit of measurement shall be the cubic metre of material measured in the compacted fill.
This item shall apply to fill constructed with material bladed directly from cut to fill including material cut from the side slope of existing fills,
pavement layers and from benches, using construction equipment such as a grader or bulldozer without having to load and haul the material to
its point of use. The quantity of material shall be computed from the cross-sections as described for items C5.2.2 and/or the authorised dimensions
of side-cuts or benches to be cut into the side slope of existing fills, superimposed thereon.
The tendered rate shall include full compensation for side-cutting the material by bull-dozing it side-ways, or by another appropriate construction
method, to fill, placing the material along with the simultaneous cutting of benches to the shape and dimensions specified followed by the
compaction of the material.
The tendered rate shall also include full compensation for preparing, placing the material, processing, shaping, watering, mixing, and compacting
the material to the densities or in the manner specified herein.
C5.2.4 Correcting rock fills that are deficient in fine material, extra over C5.2.2.4 cubic metre (m3)
The unit of measurement shall be the cubic metre of corrected rock fill.
The tendered rate shall include full compensation for procuring and furnishing approved material that passes through the 5.0 mm sieve, including all
transport, for loading and off-loading, for placing and spreading, watering and rolling, for removing all excess fines from the surface of the rock fill, and
for all other incidentals necessary for completing the work as specified.
C5.2.5 Fill in sidewalk
C5.2.5.1 Fill material in sidewalk compacted to 93 % of MDD cubic metre (m3)
C5.2.5.2 Fill material in sidewalk compacted to 93 % of MDD using labour enhanced methods of cubic metre (m3)
construction and light hand equipment.
The unit of measurement shall be the cubic metre of material measured in the compacted fill as calculated from the authorised dimensions of the
sidewalk.
The tendered rates shall include full compensation for preparing, processing, shaping, watering, mixing, and compacting the material to the
specified density or in the manner specified in the Contract Documentation irrespective of the source of the material. The tendered rates shall also
include full compensation for building up or reinstating the fill in the sidewalk.
The tendered rates shall also include for breaking down or removing and disposing of any oversize material from the road after processing.
A distinction shall be made between construction using conventional construction methods and labour enhancement methods.
C5.2.6 Fill material in shoulder widening
C5.2.6.1 Fill material in shoulder widening compacted to 93 % of MDD cubic metre (m3)
C5.2.6.2 Fill material in shoulder widening compacted to 93 % of MDD using labour enhancement and cubic metre (m3)
light hand equipment.
The unit of measurement shall be the cubic metre of material measured in the compacted fill as calculated from the authorised dimensions.
The tendered rates shall include full compensation for preparing, processing, shaping, watering, mixing, and compacting the materials to the
densities or in the manner specified herein irrespective of the source of the material.
The tendered rates shall also include for breaking down or removing and disposing of any oversize material from the road after processing.
A distinction shall be made between construction using conventional construction methods and labour enhancement methods.

C5.2.7 Construction of a trial section
C5.2.7.1 Normal fill cubic metre (m3)
C5.2.7.2 Sand fill cubic metre (m3)

C5.2.7.3 Rock fill cubic metre (m3)
C5.2.7.4 Coarse fill cubic metre (m3)
C5.2.7.5 Roller-pass compaction cubic metre (m3)
The unit of measurement for a trial section shall be the cubic metre of material processed during construction of the trial section according to the
authorised dimensions as specified in the Contract Documentation measured along the centre line of the road. A total length of at least 150 m of
trial section and no more than 200 m will be measured for payment as a trial section. The authorised depth and width of the trial sections shall be
representative of what will ultimately be constructed as per the Contract Documentation.
The tendered rates shall include full compensation for setting out the trial section, preparing and providing the plan for the specific trial section
and preparing the existing road surface where required.
The tendered rates shall also include full compensation for the application of water, all laboratory testing and for the full documentation of the
rolling techniques and combination of rollers all as specified.
C5.2.8 Breaking down oversize fill material on the road
C5.2.8.1 By normal grid rolling as per clause A5.3.7.3b) (i) to (vii) square metre-pass (m2-pass)
C5.2.8.2 By tamping roller square metre-pass (m2-pass)
C5.2.8.3 By pad foot vibratory roller square metre-pass (m2-pass)
C5.2.8.4 By vibratory roller square metre-pass (m2-pass)
The unit of measurement shall be the square metre-pass calculated by multiplying the layer surface area covered by the agreed number of roller-
passes used to break down the material satisfactorily.
The tendered rates for each square metre-pass instructed by the Engineer shall include full compensation for all supervision, labour, equipment,
fuel, materials, work and incidentals necessary for completing the work. The same rates shall be applicable should there be a reduction in the
number of roller-passes for a specific type of roller.
The tendered rates shall include full compensation for supplying the roller and removing the roller after completion of the breaking down process.
The items shall differentiate between the different types of rollers used.

C5.2.9 Removal of oversize material cubic metre (m3)
The unit of measurement shall be the cubic metre of oversize material which cannot be broken down on the road and is removed for re-crushing
or removed to spoil as instructed by the Engineer in excess of the 5 % of the compacted layer volume of oversize material included in the rates
tendered for item C5.2.2.
The volume measured for payment shall be taken as 70 % of the loose volume in excess of 5 % of the measured volume of the layer as measured
in the haul vehicles.
The tendered rate shall include full compensation for removing the oversize material from the fill layer, loading it into the hauling vehicles and off-
loading it at the agreed point of disposal.
The haul of the oversize material in excess of 5 % by volume per layer shall be measured from the point of loading/collection to the point of off-
loading as per Section A1.7 of Chapter 1.

C5.2.10 Finishing off rock fill slopes
C5.2.10.1 Finishing off rock fill slopes with soft material cubic metre (m3)
C5.2.10.2 Finishing off rock fill slopes with soft material using labour enhancement and light, hand cubic metre (m3)
equipment.
The unit of measurement shall be the cubic metre.
The volume shall be measured as 70 % of the loose volume measured in the trucks.
The soft material instructed by the Engineer to be dumped over the sides of rock fills for finishing will be measured and paid for as material in
addition to the net specified dimensions of the road prism as indicated on the road cross-sections.
The tendered rates for finishing cut or fill slopes, medians and interchange areas shall include full compensation for all labour, equipment, materials
and other incidentals and work required for finishing as specified, including the loading, transporting and disposal of any material brought down
during the finishing operations.
A distinction shall be made between construction using conventional construction methods and labour enhancement.

C5.2.11 Finishing-off fill slopes, medians and interchange areas
C5.2.11.1 Fill slopes square metre (m2)
C5.2.11.2 Medians and interchange areas square metre (m2)
The unit of measurement shall be the square metre of cut or fill slopes or medians and interchange areas finished off as specified.
The areas shall be measured from topographical surveys measured along the slopes. It shall be the sloping area between the shoulder breakpoint
and the toe of the fill in the case of fill slopes. The medians shall include the full width of the median between the inner edges of the shoulders.
The extent of median areas which are to be finished off shall be determined in accordance with the drawings.
Areas, except fill slopes, required to be lined with cast in place or precast concrete linings, kerbing, channelling or chutes, as specified, shall not
be measured and paid for under item C5.2.9. All fill slopes and channel bottoms of open drains resulting from open-drain excavations as defined
in Chapter 3, as well as the floors and sides of existing open drains that are trimmed during the clearing and shaping of existing open drains as
defined in Chapter 3, shall not be measured and paid for under item C5.2.9.
The tendered rates for finishing the fill slopes, medians and interchange areas shall include full compensation for all labour, equipment, materials
and other incidentals and work required for finishing as specified, including the loading, transporting and disposal of any material arising or brought
down during the finishing operations.

D5.2 FILL
CONTENTS
D5.2.1 SCOPE
D5.2.2 GENERAL

5.3 ROAD PAVEMENT LAYERS
CONTENTS
A5.3.1 SCOPE
A5.3.2 DEFINITIONS
A5.3.3 GENERAL
A5.3.5 MATERIALS
A5.3.8 WORKMANSHIP

A5.3 ROAD PAVEMENT LAYERS

A5.3.1 SCOPE
This Section covers the work requirements for loading at the point of supply, the hauling and off-loading at the point of use, the spreading, mixing,
watering and levelling and the compaction and finishing of pavement layer material required for the construction of the road pavement layers.
This Section also covers the work requirements for the loading of pavement layer material at the point of supply, the haulage to a central mixing
plant to add and mix water and stabilising agent with the pavement material, hauling the mixed material to a paver at the point of use and then
the construction of the pavement layer by paving, compacting and finishing the layer. This operation is known as plant-mixed, paver-laid (PMPL)
pavement layer construction.
Material for the road pavement layers is produced as specified in the relevant Sections of Chapter 4.
The addition and mixing of stabilising agents either as an integral part of the PMPL process or for some of the conventionally placed road pavement
layers that require treatment and/or stabilisation is specified in Section A5.4.
The reconstruction of existing road pavement layers is specified in Section A5.5.
A5.3.2 DEFINITIONS
The relevant definitions elsewhere in the standard specification are applicable. Additional definitions for this Section are included here.
Single-operation - a single-operation is the amount of work that can normally be carried out during the course of a single work shift using the
applicable construction equipment.
A5.3.3 GENERAL
A5.3.3.1 Sources of material
The sourcing of material shall take place as specified in Chapter 4.
Material shall be obtained from approved sources such as borrow areas, cuts, stockpiles or reclaimed road materials from existing road pavement
layers. Reclaimed road material shall be processed as specified in Section A4.3 of Chapter 4 to produce a material compliant with the material
properties specified in Chapter 4 for the particular intended use of the material, as specified in the Contract Documentation.
Material may also be obtained from compliant commercial and alternative material sources as detailed in the Contract Documentation.
Crushed stone material shall be obtained from approved sources such as quarries, commercial sources and approved cuttings.
A5.3.3.2 Use of material

The Contract Documentation shall detail the proposed layers for which the different materials are suitable, including the proposed use of
commercial materials and alternative materials.
Notwithstanding the proposed use of the various sources of materials given in the contract document the Contractor shall ensure that all material
used for the pavement layers complies with the relevant material quality as specified in Chapter 4.

A5.3.3.3 Requirements prior to the construction of any pavement layer
The first pavement layer shall not be constructed until the following construction work has been completed:
• Construction of the fill must be completed;
• Construction of the cut must be completed;
• Construction of the roadbed through a cutting in soft or hard material, must be completed;
• All over-built material on fill slopes must be removed.
The finishing of cutting slopes shall be completed prior to the construction of a subbase layer.
Before any material for a pavement layer is off-loaded onto the road for the subsequent construction of that pavement layer, the Contractor shall
obtain approval of the underlying layer from the Engineer. Immediately prior to off-loading any pavement material onto the underlying layer the
Contractor shall recheck the underlying layer to establish whether there is any localised damage or localised defects in the underlying layer, and
if so, these shall first be rectified. Wet spots in the underlying layer are dealt with as specified in Clause A5.3.3.8.
A pavement layer shall only be constructed once the underlying layer meets all the specified requirements and has been approved.
In a new cutting, or in a completed box cut, the underlying floor layer needs to be processed and constructed as roadbed preparation. The specific
roadbed preparation shall be as specified in the Contract Documentation or as instructed by the Engineer and shall take place as specified in
Section 5.1. This roadbed preparation shall be constructed before the construction of the first pavement layer takes place on the constructed and
approved roadbed preparation.
Where the in-situ material properties prove to be compliant with those for the first selected layer, the Contract Documentation or the Engineer may
specify that the in-situ material shall be processed and constructed as per the requirements for a selected layer without any prior roadbed
preparation being required.
A5.3.3.4 Compaction of pavement layer material

All material used for the construction of pavement layers shall be mixed with water to the required compaction moisture content prior to being
processed and compacted to the specified thickness, level and density. The material shall be compliant with the material requirements for each
specific layer.
Compaction shall be carried out in a series of continuous processing and compacting operations covering the full width of the layer concerned.
The length of any section of a layer being compacted shall not be more than what can be properly compacted with the available equipment in a
single-operation or shorter period when specified in the Contract Documentation.
The Contractor shall reduce the length of any layer compacted in any single-operation, and/or change the compaction process and/or change the
number of, or type of, equipment being used, if the specified thickness, level or density of the layer is not being achieved.
The type of compaction equipment used and the amount of rolling done shall be such as to ensure that the specified density, or the specified
number of roller-passes, is obtained without damage being done to any of the underlying layers due to breakdown or settlement of the underlying
layer.
The compacted layer shall be completed to the required density, thickness, levels, shape and cross-section specified in the Contract
Documentation and within the tolerances specified in this Section. All oversize material, lamination layers and any excess material shall be
removed from the compacted surface before any further pavement layers or surfacing is carried out.
A5.3.3.5 Existing or newly constructed infrastructure

During the construction of pavement layers, all existing or newly constructed drainage infrastructure such as concrete edging, kerbing and
channelling, sidewalks, lined drains, manhole covers, kerb inlets and gratings shall not be displaced or damaged.
Furthermore, no damage shall be caused to any existing or newly constructed structures such as culverts, bridges and buildings or any roadside
furniture such as road signs, guardrails, streetlights, fencing, service pipes and cables during the construction of pavement layers.
Where necessary small hand-operated compaction equipment shall be used to ensure that the specified compaction is achieved immediately
adjacent to drainage infrastructure, structures and roadside furniture.
Any items damaged during construction shall be replaced or repaired immediately by the Contractor, at no cost to the Employer.
A5.3.3.6 Tie-ins at existing bituminous surfaces

At junctions with existing bituminous surfaces, the existing surfacing and layer work near the tie-in shall be cut back in a neat, straight line so as
to ensure that the compacted thickness of the new base layer all the way up to the tie-in point, is not less than 150 mm.
A5.3.3.7 Joints between pavement layers

a) Location of joints
Pavement construction joints, or overnight stops, in each successive layer of the pavement, shall be staggered and never be directly above the
construction joint in the underlying layer.
The final manifestation of a longitudinal joint in the asphalt surfacing shall coincide with a road marking line (lane or shoulder) or with the middle
of a traffic lane as detailed in the Contract Documentation. Under no circumstances shall the longitudinal joint in the pavement base layer or in
the asphalt layer be located along a traffic wheel path.
Longitudinally, the joint between new and existing asphalt surfacing layers shall be off-set at least 100 mm from the longitudinal construction joint
between the pavement base layers.
Transversely, the joint between new and existing asphalt surfacing layers shall be off-set at least 500 mm from the transverse construction joint
between the pavement base layers.
b) Longitudinal joints
A longitudinal joint shall be formed between existing pavement layers that are to remain intact and the adjacent widened pavement layers or the
adjacent pavement layers to be reconstructed.
The construction of longitudinal joints shall commence with a saw-cut through the existing surfacing and through each bound layer (G1 and/or
G2), any stabilised layer to the depth as detailed in the Contract Documentation. After each layer has been saw-cut, the layer material on the

widening side of the saw-cut or on the reconstruction side of the saw-cut, shall be removed to sufficiently expose the layer below so that the next
saw-cut through the bound or stabilised layer beneath can be made. The position of the next saw-cut shall be at least 150 mm away from the first
saw-cut, and further away from the pavement layers that are to remain intact. This procedure shall be repeated until all the layers to be removed
have been saw-cut.
Ultimately the longitudinal joint shall comprise a series of steps that are 150 mm wide and vertically the depth of each layer unless specified
otherwise in the Contract Documentation. The saw-cut prevents adjacent intact layers from being damaged during the material processing or
reconstruction and prevents a longitudinal crack developing immediately above the widening or reprocessing location.
c) Transverse joints
A transverse joint is required between pavement layers when the road pavement length is extended or between two new sections of pavement
layer construction. A transverse joint so formed shall be perpendicular to the road centreline and the step width shall be 500 mm per reconstructed
layer. The number of 500 mm wide steps cut into the existing road pavement layers or between two new sections will be the same as the number
of constructed pavement layers unless specified otherwise in the Contract Documentation.
When upper pavement layers are bladed or milled to windrow or taken to stockpile in order to expose the underlying layer that requires
reconstruction, a transverse joint shall be constructed in the same manner as specified for the longitudinal joints, with each step being 500 mm
wide per layer that is reconstructed or extended. The process of stepping back by 500 mm, doing the saw-cut and trimming up to the saw-cut,
ahead of the next layer, shall continue until the base layer has been constructed.
Where use of a recycler is made to reconstruct a pavement layer in-situ, the transverse joint may be constructed using the recycler, without the
use of saw-cutting equipment, as instructed by the Engineer or as specified in the Contract Documentation.
A5.3.3.8 Pavement layer drainage

Each compacted and completed pavement layer shall be adequately drained to prevent water from standing on or along the completed work.
Windrows shall be removed immediately after construction to facilitate the drainage of water off the surface and to prevent scouring of the
completed work. On steep grades the Contractor may need to provide temporary berms to divert the water off the road surface at regular intervals.
No material for a subsequent layer may be placed if the underlying pavement layer has been softened by moisture. The underlying pavement
layer must first be allowed to dry out until the moisture content in the layer is below the optimum compaction moisture content. Any scouring of
the pavement layer surface caused by storm water shall be repaired and the repairs approved by the Engineer before any material for the
subsequent layer is placed.
If the underlying pavement layer cannot be adequately dried out or the water related damage cannot be satisfactorily repaired the affected layer
shall be broken up and reprocessed at no cost to the Employer.
Where pavement layers are replaced over a section of the road width, or where pavement layers are widened and the permeability of the new
layer is not the same as the adjacent existing layer, then subsoil drainage shall be installed along and below this interface as detailed and specified
A5.3.3.9 Pavement layer protection and maintenance

The Contractor shall protect and maintain the completed pavement layers at no cost to the Employer until the next layer or the surfacing has been
constructed and thereafter until the works have been taken over by the Employer.
Maintenance shall include the closing off of the constructed pavement layers to all public traffic (except traffic for property access along the route
by owners/tenants) and construction traffic except the vehicles hauling in the next layer of construction material and the immediate repair of any
damage done to the layer or of any defects in the layer. Repairs shall be carried out as instructed by the Engineer. The Contractor shall ensure
that an even and uniform surface is restored after completion of the repair work.
The base layer shall be primed as soon after construction as possible once the base layer has dried out sufficiently to a point where the moisture
content, measured at any depth within the base layer, is below 50 % of the optimum moisture content for the material. No public or construction
traffic shall be permitted on the completed base layer either before priming the layer or on the primed layer.
A5.3.3.10 Bound macadam (BM) layer protection and maintenance

The Contractor shall protect and maintain the completed bound macadam (BM) layer at no cost to the Employer until the next layer or the surfacing
has been constructed and thereafter until the works have been taken over by the Employer. Maintenance shall include the immediate repair of
any damage to the layer or of defects in the BM layer and shall be repeated as often as necessary. Repairs shall be carried out so as to ensure
that an even and uniform surface is restored after completion of the repair work.
No public traffic (except traffic for property access along the route by owners/tenants) or construction traffic other than the prime distributor and
the surfacing equipment shall be allowed on any completed BM layer.
A5.3.3.11 Water for pavement layers

Water for the construction of pavement layers shall comply with the requirements of Clause A4.1.5.18 of Chapter 4.
A5.3.3.12 Contractor prepared plans for the construction of pavement layers

The Contractor shall prepare and submit a management and utilization (M&U) plan for the construction of each individual pavement layer to ensure
that it is worked in a sustainable and sensitive manner, that the environmental impact is minimised, material use and haulage are optimised and
that costs are minimised.
The M&U plan shall at least take cognizance of the following and provide detail of the following as appropriate:
• The survey methods to be used to set out and control the levels and width of the pavement layers for each layer,
• A method statement and programme for the construction of each of the pavement layers from loading at the source of supply up to the
completion of each layer,
• Risk assessment for ensuring the material can be taken to and used directly on the road to minimize any additional stockpiling on site,
• A method statement of how the pavement layers material will be prevented from sustaining storm water damage and from becoming
excessively wet,

• A method statement for the construction of trial sections where specified or where requested by the Contractor and especially for stabilised
layers, crushed stone layers and macadam layers,
• A method statement of how oversize material will be dealt with,
• A method statement of how work will be carried out in restricted areas,
• Measures to comply with the general and specific conditions of the road environmental management plan,
• Measures to comply with safety regulations and obligations in terms of the relevant Health and Safety Acts and Regulations,,
• The full quality and process control testing detail for the applicable materials tests along with the frequency and quantity of such testing for
each constructed section of each layer type to ensure full compliance of the constructed layer in terms of compaction density and material
quality,
• The full quality and process control testing, frequency and quantity of tests, for stabilised layers, visually and tests in the laboratory, and
plan will be submitted for review. The construction of a particular layer shall only commence once the Contractor’s M-&U plan for that layer has
been reviewed and accepted by the Engineer. The Engineer shall respond within one week after receiving an M&U plan.
A5.3.4 DESIGN BY THE CONTRACTOR/PERFORMANCE BASED SYSTEMS

The Contractor shall be permitted to submit an alternative pavement design as part of a performance based system.
A5.3.4.1 Catalogue pavement design

An alternative pavement design based on approved catalogue designs may be submitted when the average annual daily traffic (AADT) is less
than 5 000. A 15-year pavement design life shall be required.
A5.3.4.2 Mechanistic pavement design

An alternative pavement design based on a mechanistic design process, may be submitted when the project details meet the following criteria;
a) AADT between 5 000 and 50 000
A 20-year pavement design life is required, and a full Life Cycle Cost Analysis shall be required for the alternative pavement design.
b) AADT in excess of 50 000
A 25-year pavement design life is required, and a full Life Cycle Cost Analysis shall be required for the alternative pavement design.
A5.3.4.3 Other pavement design methods

An alternative pavement design may also be submitted, based on other accepted pavement design methods such as AASHTO, DCP, Empirical
or any other, when the project details meet the criteria of Clause A5.3.4.2.
A5.3.5 MATERIALS
A5.3.5.1 Material information
The required material properties for each individual pavement layer for a specific pavement design shall be clearly specified in the Contract
Documentation.
The Contract Documentation shall specify which types of materials are to be used for a PMPL layer.
Any anticipated mechanical modification of material shall be stated in the Contract Documentation.
A5.3.5.2 Pavement layer thickness and compaction requirements

a) Pavement layer thickness requirements
The compacted pavement layer thickness shall be as specified in the Contract Documentation.
The thickness tolerances specified in Clause A5.3.8.4b) shall apply.
b) Gravel and soil pavement layer compaction requirements (G4B to G9 material)
The minimum compacted dry density of a gravel or soil pavement layer shall be as specified in Table A5.3.5-1 unless specified otherwise in the

Table A5.3.5-1: Minimum compaction densities for gravel and soil pavement layers
Layer Compaction as % of maximum dry density (MDD)
Lower selected layer 93 %
95 % for gravel layers

Upper selected layer
100 % for sand layers (97 % when specified in Contract Documentation)
Wearing course layer 95 %
Shoulder layer 95 %
95 % for unstabilised layers
Lower subbase layer 95 % for chemically stabilised layers
100 % for sand layers
Upper subbase layer 95 % for chemically stabilised layers
100 % for sand layers

Base layer
97 % for chemically stabilised layers
In restricted areas the compacted dry density of the individual pavement layers shall also comply with the requirements given in Table A5.3.5-1
unless specified otherwise in the Contract Documentation.
c) Crushed stone pavement layer compaction requirements (G1 to G4A and G5A materials)
The minimum compacted dry density of a crushed stone pavement layer shall be as specified in Table A5.3.5-2 unless specified otherwise in the
Table A5.3.5-2: Minimum compaction densities for crushed stone pavement layers
Compaction as % Maximum Dry Density (MDD) or as % Bulk Density (BD) or as %
Layer
Apparent Density (AD)
95 %of MDD for unstabilised layers

G4A and G5A lower subbase layer
95 % of MDD for chemically stabilised layers
97 %of MDD for unstabilised layers

G3, G4A and G5A upper subbase layer
97 % of MDD for chemically stabilised layers
G3 and G4A base layer 98 % to 100 % of MDD (for G3 and G4A) or 85 % of BD for G3 only
88 % of BD for Road category C and D (TRH 4, Table 1)

G2 base layer
86 % of AD for Road category A and B (TRH 4, Table 1)
86 % of AD for Road category C and D (TRH 4, Table 1 for road categories)

G1 base layer
88 % of AD for Road category A and B (TRH 4, Table 1 for road categories)
PMPL pavement layer (lean mix concrete) Cube crushing strength as specified in Contract Documentation. No density requirement.
The density of the compacted crushed stone base layers (G1 and G2 layers only) shall be tested to the full depth of the layer using a nuclear
gauge.
In restricted areas the in-situ dry density of the crushed stone subbase and base layers shall also comply with the requirements given in Table
A5.3.5-2 unless specified otherwise in the Contract Documentation.
d) Bound macadam (BM) layer

The minimum in-situ density of a BM layer shall be within the range as specified in Table A5.3.5-3. The Contract Documentation shall specify the
actual applicable apparent density along with the construction method and the type of BM.

Either the dry-bound or wet-bound construction method can be used to construct the BM rock matrix.
Table A5.3.5-3: Minimum compaction density for BM pavement layers
Layer Compaction density as % of apparent density (AD)
Bound macadam (BM) layer – dry-bound 84 % to 86 %
Bound macadam (BM) layer – water-bound 88 % to 90 %
After the construction of the BM rock matrix to the required compaction density the subsequent treatment of the compacted BM layer can vary
and shall be specified in the Contract Documentation or instructed by the Engineer.
A5.3.5.3 Bound macadam layers

There are various BM layers that can be constructed, each with different material usage and different methods of construction.
The Contract Documentation shall specify which BM shall be constructed.
Table A5.3.5-4 describes the different BM layers.
Table A5.3.5-4: Different BM pavement layers
BM layer description Key layer characteristics
Single size rock matrix, usually 63 mm, filled with dry fine filler aggregate using compaction
Dry-bound macadam (DBM)
equipment only. Smooth swept surface.
A DBM slushed afterwards by saturating the filled rock matrix, usually 63 mm, and rolling
Water-bound macadam (WBM) with a steel drum roller. Where the climate does not allow the fine filler aggregate to dry
sufficiently, it may be washed into the coarse aggregate. Smooth swept surface.
Construct a DBM or WBM. Broom away excess aggregate fines and some of the fine filler
Partially penetrated macadam (PPM) aggregate in the exposed open voids. Rough swept surface. Apply slurry which will therefore
only penetrate partially.
Construct a PM followed by the application of a slurry using a crusher-sand/sand with

Slurry-bound macadam (SBM)
emulsion. All voids to be completely filled with the emulsion slurry
Construct the lower portion of the layer as a DBM or WBM. Construct the upper portion of
Composite macadam (CM)
layer of SBM using 50 mm or 37,5 mm aggregate. See Table A4.1.5-8.

Construction equipment to carry out the construction of the pavement layers shall comply with the requirements of Clause A1.2.6 of Chapter 1.

A5.3.7.1 Controlling pavement layer thickness
a) Placing and spreading layer material
All material placed in position before compaction shall be spread evenly over the entire surface of each layer to be compacted and the quantity of
material spread shall be such that each layer will comply with the requirements for thickness as specified in the Contract Documentation, when
measured after compaction.
The Contractor shall ensure that segregation of the material into finer and coarser fractions does not occur during any of the stockpiling, loading,
hauling, spreading and subsequent mixing operations.
b) Minimum pavement layer thickness in transition areas
Where the thickness of an existing gravel layer needs to be supplemented and the thickness of the added material after compaction will be less
than 100 mm, the existing layer shall be scarified to a depth that will give a combined compacted layer thickness of at least 150 mm after
compacting the loosened existing material and the added material as one layer unless specified otherwise in the Contract Documentation.
Where the thickness of an existing crushed stone subbase or base layer needs to be supplemented then the entire existing subbase or base layer
shall be scarified and blended with the added material. The blended material forms a composite layer and it shall be compacted as a single layer
if the compacted layer thickness will be less than 175 mm. The layer shall be compacted in two equal thickness layers when the final compacted
layer thickness will exceed 175 mm unless the Contractor has demonstrated in a trial section that a thicker layer can be compacted successfully.
A5.3.7.2 Combining materials

The specific material requiring to be combined shall be specified in the Contract Documentation or the material shall be combined as instructed
by the Engineer.
a) Combining materials from various sources in stockpile
Materials from various sources requiring mixing and that cannot be taken directly to the point of use, shall be stockpiled and subsequently loaded
as specified in Clauses A4.1.7.2g) and A4.1.7.3b) of Chapter 4.

b) Combining recovered material
Recovered material from windrows, from stockpile floor areas, from oversize material, or from any area where there is an excess of material shall
be combined and re-used. Screening, or crushing and screening, of the recovered material or combining it with some new material may also be
required to comply with the material specifications of the layer for which it is subsequently to be used.
A5.3.7.3 Construction of gravel pavement layers

a) Construction
All material to be used for the construction of gravel pavement layers shall be checked at the source of supply for compliance with the material
properties specified in Chapter 4 before being loaded and hauled to the point of use or to the central mixing plant for a PMPL pavement layer.
Oversize material up to a maximum of 5 % by compacted volume may be hauled to the point of use on the road where it shall be broken down by
using appropriate compaction rollers. The remaining oversize material shall then be bladed out of the layer or removed by hand on the road.
Where this material is hauled to a central mixing plant for a PMPL pavement layer, the material shall be screened and the oversize then loaded
and hauled to a spoil site or to a crusher, for further processing.
Material containing more than 5% by volume of oversize material shall not be hauled to the point of use on the road unless it can be demonstrated
that the oversize material can be broken down on the road and the Engineer has provided an instruction for this work to take place.
When longitudinal construction joints are necessary, they shall be constructed in the positions detailed in the Contract Documentation.
Care shall be taken during the loading, hauling and dumping operations to prevent segregation of the material.
b) Breaking down pavement layer oversize material
Oversize material transported to the point of use as per Clause A5.3.7.3a) or oversize material already at the point of use, shall be broken down.
The Contractor may employ any preferred methods and equipment to break down the material. However the effectiveness of the Contractors method
shall be assessed against normal grid rolling, to establish the norm for the degree of breaking down to be attained by any alternative method.
Normal grid rolling shall be instructed by the Engineer and shall mean the following.
(i) The material shall be placed or bladed to the one side of the road to provide working space for breaking-down the material.
(ii) A portion of the material shall be spread in a thin layer on a compacted surface to promote effective breaking-down of the material,
and to a width which the grid roller shall be able to cover in a single pass.
(iii) The grid roller, which shall proceed at a speed of at least 12 km/h and shall have a minimum mass of 13,5 tons, shall do four
complete roller passes over the material.
(iv) Any material that is still oversize shall be removed and taken to a designated spoil site or to a crushing plant to be crushed
(v) The broken-down material shall be placed in a windrow to the opposite side of the material still to be broken-down
(vi) Repeat steps (ii) to (v), then place the second windrow next to the first windrow and mix the two windrows.
(vii) Repeat steps (ii) to (vi) until all the material that needs to be broken down has been treated.
If normal grid rolling does not break down the material acceptably, the Engineer shall instruct either additional normal grid rolling, or crushing and
screening to take place. Additional grid rolling means a repeat of the normal grid rolling detailed in points (i) to (vii) above.
c) With grader and conventional equipment
Before the pavement layer material is compacted, it shall first be thoroughly mixed by grader and disc plough, so as to obtain an even mix of the
pavement material. The fine and coarse material shall be mixed evenly throughout the layer in the transverse, vertical and longitudinal direction.
Unless the material is already too wet, additional water shall be sprayed evenly over the spread pavement layer material using a water tanker.
d) With grader and specialised equipment
Before the pavement layer material is compacted, it shall first be thoroughly mixed using equipment such as a recycler so as to obtain an even
mix of the pavement material. The fine and coarse material shall be mixed evenly throughout the layer in the transverse, vertical and longitudinal
direction.
To ensure thorough mixing in a transverse direction when using a recycler, cross-mixing of the material may sometimes be required.
Unless the material is already too wet, additional water shall be sprayed evenly over the spread pavement layer material by the recycler during
the final mixing pass.
The addition of water and mixing of the material can all take place simultaneously when a recycler is used.
e) Moisture control
The requirements of this clause e) are applicable to both clauses c) and d) above.
All additional water shall be uniformly mixed into the material to bring it to a moisture content to suit the specific compaction equipment used.
When adding water, allowance shall be made for the loss of any water due to evaporation during the mixing and compaction operations which
may occur under hot and/or windy weather conditions.
If the moisture content of the material is in excess of the compaction moisture content required to achieve the specified compaction density the
wet material shall be replaced with dry material or processing shall cease and the material left to dry out until the required compaction moisture
content has been reached. During compaction the material shall not display any signs of still being too wet, such as pumping or movement. The
pavement layer material shall be compacted to the correct layer thickness and density as specified.
f) With paver and other equipment
Before the pavement layer material is compacted the mixture shall be spread and placed by a mechanical paver on the underlying layer to the
required width and to a thickness and levels which are compliant with the tolerances specified in Clause A5.3.8 after final compaction. Segregation
of the materials shall be prevented and the layer shall be free from pockets of coarse or fine materials.
Immediately prior to paving the material, the underlying layer shall be dampened and kept damp (not wet) until the layer is paved.
A5.3.7.4 Processing coarse gravel subbase or base layer

Coarse gravel containing mostly non-plastic or slightly plastic soil fines and used in the construction of a gravel subbase or base layer, shall
require slushing and rolling in addition to the specified compaction, in order to obtain a firm, well-knit surface.

After being processed and compacted, the layer may require to be well watered by the Contractor over short sections at a time and then slushed
and rolled with pneumatic and/or vibratory compactors. Watering and rolling shall continue over a section until excess fines have been brought
to the surface of the layer. Such excess fines shall be uniformly spread over the entire surface of the layer by means of stiff mechanical or hand
brooms.
Watering, rolling and brooming shall continue until all surface areas deficient in fines have been corrected. All excess fines shall then be broomed
off the surface of the layer without loosening the surface texture of the completed layer.
A5.3.7.5 Construction of gravel shoulder

Shoulder material shall be spread, watered, processed and compacted in accordance with the specifications for a pavement layer.
Where the gravel shoulder layer is to be constructed with the same gravel material as for the base layer, it shall be constructed simultaneously
with the base layer.
Where a base is to be constructed with different gravel or with crushed stone material, the shoulders shall first be constructed and then neatly cut
to the required line and level to provide lateral support for the edges of the new base layer material while it is being compacted. Care shall be
taken not to contaminate the base material with the shoulder material. The Contractor shall ensure that the subbase layer and the base material
that has not yet been compacted is adequately drained at all times by means of temporary drainage channels or pipes passing through the gravel
shoulder layer.
Where an asphalt base layer is to be constructed, the shoulders shall be constructed after the completion of the asphalt base layer.
A5.3.7.6 Construction of crushed stone layer

a) Transportation of crushed stone subbase and base material
Compliant crushed-stone material shall be loaded at source, hauled to the road and off-loaded along the middle of the road width being
constructed, in a pre-determined heap volume and spacing to ensure sufficient quantity so that the completed layer will comply with all the
requirements in regard to layer thickness, level, cross-section and compaction density. Allowance shall also be made when determining the heap
volume and spacing for sufficient additional material to be off-loaded to enable the layer to be properly mixed and cut to shape without segregation
of the material taking place. Segregation is manifest by fine and/or coarse areas that develop in the exposed surface of the layer.
b) Processing of crushed stone subbase and base layer
The day before spreading and mixing the dumped material, the heaps shall be flattened slightly. The crushed stone shall then be dampened, by
a watercart driving slowly over the flattened heaps. Watering shall cease when water starts to seep out from under the crushed stone heaps and
the material shall then be left to stand until the next day.
Spreading and mixing of the material shall then be carried out, adding water as necessary. The water shall be sprayed on by means of a watercart.
Mixing shall only be done by means of a grader by simultaneously watering and cutting the crushed stone from side to side across the underlying
layer, starting from the middle of the layer width where the material was initially dumped. The grader shall move at an even pace with a fully laden
blade. No material shall pass under the blade as this will result in segregation. The crushed stone shall be picked up cleanly from the underlying
layer, and contamination by cutting into the underlying layer or an adjacent gravel shoulder shall be avoided. The optimum moisture content for
compaction is correct when excess moisture becomes visible or glistens on the larger aggregate but just before the addition of any more water
will result in the fine material being washed away.
Excessive mixing must be avoided as it tends to segregate the crushed stone and alter its grading.
After spreading and mixing of the material has been completed, the material must be shaped into a layer to the correct cross section, levels,
thickness and slope ready for compaction. Any shortfall in levels of the material must be corrected by adding crushed stone material. A shortfall
over a length less than 20 m shall be corrected by mixing the additional material into the newly processed material by means of the ripper teeth
of the grader, or alternatively to mix the additional crushed stone and water in the correct proportions in a large concrete mixer and spread the
material over the shortfall area. When the shortfall occurs over a length that exceeds 20 m, all the material over at least 100 m shall be re-mixed
with additional material.
c) Paver laid crushed stone subbase and base
The Contractor may elect to mix and spread crushed stone subbase and/or base material by means of a mixing plant and a paver unit. The
construction of a trial section using this equipment shall be constructed before any crushed stone subbase or base layers are constructed on the
underlying layer.
A5.3.7.7 Initial compaction of a G1 crushed stone base layer

Initial compaction of the crushed stone base layer shall commence immediately after completion of the spreading, dampening, mixing and shaping
of the material as per Clause A5.3.7.6b). The Contractor shall provide compaction equipment that is capable of compacting the crushed stone
layer to the required density using the process specified below.
Only a vibratory smooth drum roller or a combination of smooth drum and pneumatic tyre rollers shall be used for the initial compaction. Normally
no grid or pad foot rollers shall be used as these rollers will alter the grading. The first pass of the vibratory roller shall be in static mode in order
to smooth out the surface of the layer prior to compaction. Thereafter vibration at low frequency and high amplitude for compaction of the lower
part of the layer shall be carried out, followed by vibration at high frequency and low amplitude for final compaction of the upper part of the layer.
To prevent shoving of the crushed stone, rollers shall always initiate compaction of a crushed stone layer from the outside edge of the road
adjacent to the shoulder material towards the middle of the layer width on straight sections where there is a cross-fall. In a super elevation in a
curve, the compaction shall commence from the lower or inner edge of the road towards the higher or outer edge.
The roller shall cover the entire road width equally. Compaction shall continue until the material is stable and displays no movement under the
roller wheels and leaves no tyre marks of the roller in the crushed stone layer.
After the compaction is completed, a final slight full-width cut shall be carried out when necessary to ensure that the layer has no coarse or stony
patches but an evenly-graded surface matrix. The layer must then again be rolled with pneumatic tyre or smooth drum static rollers to ensure that
it is stable enough and ready for the final slush-compaction. The maximum compacted thickness of any crushed-stone layer compacted in one
process shall be 150 mm, unless specified otherwise in the Contract Documentation.
A5.3.7.8 Slush-compaction of a G1 crushed stone base layer

After completion of the initial compaction of the crushed stone base layer, short sections of the layer surface, each section about 40 m to 60 m

long, shall be thoroughly watered, rolled and slushed by means of steel wheeled rollers or a combination of steel wheel rollers and pneumatic tyre
rollers. The Contractor shall provide compaction equipment that is capable of slush compacting the crushed stone layer to the required density
using the process specified below.
Slush-compaction shall start at the high side of the road so that the water can flow to the low side. No movement of the layer under the roller
wheels shall be observable during the initiation of the slush-compaction. If the layer becomes unstable, it is an indication that insufficient bearing
capacity has been achieved during the initial compaction. The slush-compaction shall then be halted, and the layer allowed to dry and
subsequently to receive additional initial compaction before commencing again with the slush-compaction process.
The slush-compaction process shall continue until fines are brought to the surface. Fines shall mean sand or material larger than 0,075 mm up to
5,0 mm, and silt material smaller than 0,075 mm. The slush-compaction process is completed when the slushing water becomes clean and there
is subsequently an absence of air bubbles being expelled from the layer.
The slush thus formed, shall be uniformly broomed over the surface to simultaneously correct any areas still deficient in fines, whereupon the
excess fines shall be broomed from the surface of the layer. Brooming shall be done by using hand brooms, or by using mechanical rotary
brooms with soft to medium stiffness bristles, or a combination of hand and mechanical brooms. Care shall be taken not to dislodge the coarse
aggregate in the surface of the layer during the brooming process or otherwise disturb the aggregate mosaic.
During slushing operations, the surface must not be rolled out of shape. The slushing process shall be carried out on each short section in one
continuous process, and each section shall be completed before the next section is commenced. After completion of the slushing and brooming
process, when the surface of the layer is wind dry, the surface shall be given a one roller-pass with a static steel-wheeled roller. This finally embeds
the surface aggregate.
The completed layer shall be firm and stable with a closely-knit surface of aggregate exposed in a mosaic pattern. The surface must have a good
particle distribution without segregated areas of either excessive fines or of coarse material with a shortage of fines. The surface must be free
from any lamination layers and free from corrugations. The following characteristics are indicative of a well-constructed crushed stone layer:
• Most of the coarse aggregate lies on its largest surface dimension which is the most stable orientation.
• The exposed surface of the layer, although textured, feels smooth.
• All sizes of coarse aggregate larger than 5,0 mm can be seen.
• The surface has a uniform appearance across and along the road.
• The surface has a tightly interlocked mosaic of the coarse aggregate and less than 5 % of the mosaic area has only fine aggregate visible.
• Less than 5 % breakdown of the larger particles by area.
• The dried slush broomed off the road only comprises P0,075 mm silt.
• Tapping the layer with a geological hammer produces a distinct high frequency or ringing sound.
Slush-compaction of the crushed stone base layer is mandatory and shall be carried out within 48 hours after completion of the initial compaction.
Even if the specified density is achieved without slushing or before completion of the slushing process, the full slush-compaction process must
still be completed.
A5.3.7.9 Construction of a plant mix paver laid (PMPL) layer

a) Mixing and transportation of PMPL material
Mixing shall be done at a location off the road by means of a central mixing plant. Mixing the materials on the road shall not be allowed. The
method of introducing the various materials comprising the final mix shall be confirmed during the construction of the trial section. The method
used shall consistently produce a mix with the required proportions. Any inconsistent mix shall be rejected.
The mixed material shall be loaded into the trucks used for transporting the material in such a manner that segregation of the material does not
take place during loading.
The loss of moisture between the mixing moisture content and the compaction moisture content of the mixed material shall not be more than 5 %
of the measured mixing moisture content. When necessary, the trucks shall be provided with protective covers to restrict the loss of moisture to
less than 5 %.
b) Compacting a PMPL layer
(i) Crushed stone
The spread mixture shall be compacted at or near the optimum moisture content. The moisture content added in the mixing plant
shall make allowance for any moisture losses that may occur during loading, transporting or paving the material.
The completed compacted layer shall have a dry density of not less than that specified in the Contract Documentation and the
Contractor may select any suitable compaction technique to achieve this required compaction, subject to the following construction
limitations:
• The initial compaction shall be carried out with construction equipment that will achieve stability of the layer so that subsequent
compaction can take place without displacement or deformation of the layer. The rolling pattern shall be so designed as to
retain the shape of the layer;
• The compaction equipment shall be adequate for obtaining the specified density within the specified time limits in Table
A5.4.3-1 when the PMPL material has been stabilised;
• The compaction equipment and techniques shall be capable of producing the specified surface level, layer density and finish;
and
• If the PMPL crushed stone layer is stabilised then it shall not be slushed as specified for untreated crushed stone layers. If
water is added during or after the compaction process to the stabilised mix, it shall be carefully controlled. Excessive
application of water that will alter the ratio of the cementitious content to water (c/w ratio) at the compaction moisture content
by more than 5 %, shall not be allowed.
(ii) Wet lean-mix concrete
Compaction to a specified density by normal rolling techniques will not be required, but the paver shall be fitted with a vibrating

screed capable of thorough compaction of the material and striking it off to a smooth dense surface finish.
c) Construction joints
At the end of each single-operation, or when a single-operation is delayed or stopped for more than two hours, a construction joint with a vertical
but unformed face, shall be made in the thoroughly compacted material, at right angles to the centre line of the road. Material that is not thoroughly
compacted shall be removed to spoil.
PMPL material to continue with the progress of the single-operation or to commence the next single-operation shall not be placed until the
construction joint has been prepared.
d) Finishing a PMPL layer
The stabilised crushed stone pavement layers and wet lean-mix concrete pavement layers shall have a uniform consistency.
All coarse and any other segregated areas shall be removed. The edges of the holes so formed shall be prepared in the same manner as a
construction joint with vertical faces. The vertical faces shall be prepared with a slurry of cement and water. The holes shall then be backfilled with
the same PMPL material as in the layer being repaired. The material shall be compacted to the same density as the layer by rolling or vibrating to
suit the layer being patched and then finished off to the required level. Such patches shall be cured as specified in Section A5.4.
Any portion of the pavement layer which does not meet the specified strength, density and riding quality shall be removed and replaced at no cost
to the Employer.
A5.3.7.10 Construction of a bound macadam (BM) layer

Before any BM layer is constructed, the following requirements shall be met:
• The underlying layer shall comply with the requirements for the layer concerned.
• The BM layer shall, where specified, be supported along the outer edges by edge restraints as detailed in the Contract Documentation
• A trial section shall have been constructed, tested and accepted as specified in the Contract Documentation.
a) Construction of an edge restraint
A concrete edge restraint such as a concrete channel, or a kerb and channel combination, or a gravel shoulder, shall be constructed to support
the edge of the BM layer prior to the construction of the BM layer.
Concrete kerbs and channels serving as edge restraints shall not be displaced or damaged during construction activities. A gravel shoulder
constructed as an edge restraint shall not be damaged during construction activities and shall not be allowed to contaminate the BM layer.
Any edge restraint damaged during construction shall immediately be replaced or repaired by the Contractor at no cost to the Employer.
b) BM construction methods
The BM layer shall be placed using labour enhancement and then compacted with conventional compaction equipment.
c) Spreading the aggregate
Compliant coarse aggregate shall be dumped in quantities sufficient to ensure that a layer of the specified final compacted thickness can be
constructed. The dumped material shall be evenly spread by hand, or with a grader / mechanical paver to the line and level that will allow the
compacted layer to comply with the final line, level and thickness required in the Contract Documentation.
Depth guides shall be used to control the thickness of the layer and the surface levels shall be checked at intervals of not more than 2,0 m. All
high and low spots shall be corrected by removing or adding stone as required.
d) Initial compaction
This initial compaction process or dry rolling is applicable for all the different BM layers listed in Table A5.3.5-4.
After the coarse aggregate has been spread, the layer shall be lightly compacted with appropriate rollers and any irregularities that may appear
in the surface of the layer shall continue to be corrected by removing or adding coarse aggregate, as the case may be. This operation shall be
repeated until the surface is uniformly smooth, free of irregularities and in accordance with the specified level and thickness tolerances.
Once the layer is free from irregularities it shall be compacted over its full width using low amplitude, high frequency, vibrating rollers of static
mass not less than 8 tons. Rolling shall progress gradually from the low side of the layer by uniformly lapping each preceding pass of the roller by
one half the width of the roller drum and shall continue until the entire area of the layer has been covered. Rolling shall continue until the coarse
aggregate has been thoroughly keyed and compacted and no movement of the aggregate under the rollers can be detected. The use of smaller
vibratory rollers may be used in restricted areas or as instructed by the Engineer.
Should any irregularities exceeding 10 mm when tested with a 3,0 m straight edge, develop in the surface of the layer during the course of rolling,
such irregularities shall be corrected by loosening the surface over the affected area and repacking the stone and rolling the area again until the
level requirements are met. The Contractor shall use 28 mm size aggregate where necessary to take out minor slacks or depressions.
The compacted coarse aggregate layer shall not be left uncovered by fine material for any prolonged period. If any disturbance of the compacted
stone layer occurs before the fine aggregate is spread over it, the stone layer shall be levelled again.
e) Adding fine aggregate and dry rolling
After completion of the initial dry rolling and the compacted coarse aggregate layer has been accepted, a layer of dry fine aggregate shall be
evenly applied over the surface of the coarse aggregate in a layer thickness not exceeding 15 mm.
At the time of processing, the moisture content of the fine aggregate shall not exceed 4 %. Dry rolling shall be continued with vibrating rollers until
all the fine aggregate has settled into the coarse aggregate. During this process it may be necessary to broom the surface with hand brooms to
assist in the distribution of the fine aggregate. A further layer of fine aggregate shall then be applied and spreading, rolling and brooming of the
fine aggregate shall continue until no more fine aggregate can be worked into the voids in the coarse aggregate.
All excess fines shall be swept off the surface to leave behind a tightly knit surface. An occasional light spray of water may be required to keep
the surface adequately bound until it is primed.

f) Wet rolling and slushing
When no more fine aggregate can be worked in dry, the layer shall be well watered, using water tankers fitted with sprinkler bars to ensure an
even application of the water, or applied by means of hand operated pressure sprayers. Additional fine aggregate shall be added when necessary
and a slushing process consisting of watering, rolling and brooming shall commence using suitable pneumatic tyre rollers, in conjunction with
suitable static steel drum rollers. The slushing process shall continue until a dense layer with minimum voids between the coarse aggregate and
a firm base with a closely-knit surface, is obtained, free of areas of segregated materials, loose aggregate and any other irregularities.
All excess fines shall be swept off the surface and the layer shall be allowed to dry out sufficiently before proceeding with the next stage of the
process.
g) Surface finish of BM layer
Excess BM material shall not be spread over the adjacent sidewalks, shoulders or the side fills, but shall be loaded and removed. The excess BM
material shall not be re-used unless it has first been separated into its constituent parts and tested to ensure compliance with the material
requirements.
The finished surface of the BM layer shall be true to level and cross-section, be uniform and smooth, free from corrugations, bumps and
depressions.
Any section of base that remains non-compliant after standard remedial measures have been carried out shall be broken up and reconstructed.
The non-compliant section of base shall be removed over the full depth of the layer including clearing the fine aggregate away and the section
shall be reconstructed.
The BM layer shall then be further completed and surfaced as detailed in the Contract Documentation and specified in Chapter 10: Surface
Treatments.
A5.3.7.11 Brooming and priming of BM layer

When the BM fine aggregate material has dried off to below 50 % of the OMC of the infill material for the BM layer, the surface shall be swept
clean to remove any loose surface fines and other material that may have been deposited on the surface after it was compacted.
The brooming operation shall not remove fines from between the coarse aggregate. A rough and/or loose surface caused by incorrect brooming
is not acceptable.
When the cleaned surface of the layer has been accepted, the prime coat shall be applied in accordance with the product details and application
rates specified in the Contract Documentation and the specification in Chapter 10: Surface Treatments.
A5.3.7.12 Construction of trial sections

a) Trial sections
The trial section shall demonstrate the capability of the Contractor to construct the pavement layer or layers in accordance with the specification.
The trial section shall be constructed with the same materials and equipment as those intended for use by the Contractor for the final pavement
layer in the works. The surface regularity of any base layer in a trial section shall be checked for compliance.
A trial section shall be a full layer-width and at least 150 m long with a maximum length of 200 m. The minimum quantity of material to be crushed,
stockpiled or hauled to site prior to the construction, testing and approval of the trial section shall be determined by the Contractor. Sufficient
material should be produced or obtained from commercial sources so that the compliant material shall be representative of what will ultimately be
produced for the entire project. The use of compliant material for the trial section shall not relieve the Contractor of the responsibility to produce a
compliant finished layer.
The final length and width of the trial section which shall be specified in the Contract Documentation, shall be constructed in one continuous
operation and shall then be submitted for approval. The Contractor shall also demonstrate the proposed method(s) to be used for making the
construction joints.
The Contractor shall programme to proceed with the construction of the actual pavement layer in the works, at least 10 working days after the
completion of the compliant trial section or such earlier time when testing of the trial section has been completed and the trial section has been
accepted by the Engineer. In the event of a non-compliant trial section, the Engineer shall instruct the Contractor to construct a further trial section,
which shall then be regarded as the initial trial section.
A non-compliant trial section shall be removed and disposed of by the Contractor at no cost to the Employer.
A compliant trial section shall be reimbursed only when it complies with all the requirements of the specification and has been accepted. The
mixing process and equipment shall remain unaltered for all subsequent layer construction for which the trial section was constructed, unless
otherwise instructed by the Engineer.
When the Contractor:
• changes the method of construction, or
• changes the construction equipment, or
• changes the materials, or
• changes the mix used, or
• changes the rate of paving for the construction of the layers in the works,
after the acceptance of a compliant trial section, the Engineer may instruct that a new trial section be constructed as specified in the Contract
Documentation.
b) Compliant supporting layer for a trial section
The trial section for a stabilised layer, a crushed stone layer, a PMPL layer or a BM layer shall be constructed on a compliant supporting selected-
or subbase layer. The supporting layer must be properly compacted to the specified density and be free from any defects.
If there are no constructed, compliant lower pavement layers ready to allow for the construction of the specific trial section at the programmed
time in terms of the construction programme, the Contractor shall prepare a trial section area off the site of the works. This will enable the
construction, testing and approval of a trial section to be carried out before excessive quantities of material are crushed and stockpiled.

The surface of the supporting or lower layer shall be dampened prior to placing and spreading the pavement layer material for the construction of
the trial pavement layer on it.
c) Trial section for a stabilised layer
Before commencing the construction of stabilised layers the Contractor shall demonstrate by constructing a trial section that the proposed
equipment and procedure to be used will result in constructing the layers in accordance with the specification.
The trial section shall be constructed in its proper position in the pavement. The stabilised material properties used for the trial section will be
tested. One of the key properties shall be to establish if the agent is working as per the design. The surface finish obtained, the curing process as
well as any potential stabilisation cracking, shall l also be monitored and documented. Only when such a trial section has been satisfactorily
constructed and accepted shall the Contractor be permitted to proceed with construction of the stabilised layer in the permanent work.
After acceptance of the trial section, the mixing process and equipment shall remain unaltered unless otherwise approved by the Engineer.
d) Trial section for a crushed stone layer
Before commencing with the construction of any crushed stone subbase or base layer the Contractor shall construct a trial section. The following
Clauses listed in Table A5.3.7-1 are applicable for the construction of this trial section.
Table A5.3.7-1: Clauses applicable to the construction of crushed stone layers
Clause Description
A5.3.7.6 Construction of crushed stone layer
A5.3.7.7 Initial compaction of a G1 crushed stone layer
A5.3.7.8 Slush-compaction of a G1 crushed stone layer
During the construction of the trial section these Clauses shall be validated and/or modified where necessary. Any resultant modifications of these
Clauses shall then be implemented during the subsequent construction of the particular crushed stone layer.
The trial section shall establish or verify the following specific aspects:
• The spacing between the off-loaded heaps of crushed stone;
• Compaction moisture content and the compaction factor;
• Compaction passes, compaction frequency and roller amplitude settings;
• The pre-shape level to allow for settlement during compaction;
• The types and method of operation of compaction equipment during slush-compaction of G1 material;
• How long the slush-compaction process shall continue until there are no more air bubbles, the expelled water is clean and movement or
‘heaving’ under compaction has ceased;
• Brooming equipment and the brooming process;
• Progressive development of compaction density in the layer;
• Surface finish evaluation;
• Minimum construction base width where there is no shoulder containment, to ensure that the specified density is achieved across the full
travelled roadway width;
• Grading and plasticity index, post-construction; and
• Approximate drying out time until the moisture content has been reached to allow the layer to be primed.
• The surface regularity shall be checked for compliance.
e) Trial section for a PMPL layer
Before commencing with the construction of the specified PMPL pavement layer in the works, the Contractor shall construct a trial section. The
following Clauses listed in Table A5.3.7-2 are applicable to the construction of this trial section.
Table A5.3.7-2: Clauses applicable to the construction of a PMPL layer
Clause Description
A5.3.7.3 Construction of gravel pavement layers
A5.3.7.9 Construction of a PMPL layer
During the construction of the trial section the specification of the Clauses referenced in Table A5.3.7-1 shall be validated and modified where
necessary. Any resultant modifications of these Clauses shall be implemented during the subsequent construction of the PMPL layer in the works.
f) Trial section for a bound macadam (BM) layer
There are several types of BM layers. The Contract Documentation shall specify which specific BM layer shall be constructed for the project and
this BM layer shall be constructed for the trial section. The different BM layers are listed in Table A5.3.5-4.
No BM pavement layer material, other than the compliant material required for the actual trial section, shall be placed on the road prior to the

construction of a compliant BM trial section. Any modifications to the material or to the processing methods that result from the trial section shall
be implemented for the construction of the BM pavement layer material.
The following Clauses listed in Table A5.3.7-3 are applicable to the construction of the BM trial section.
Table A5.3.7-3: Clauses applicable to the construction of a BM layer
Clause Description Construction comments
A5.3.7.10.1 Construction of an edge restraint Required for all BM layers
A5.3.7.10.2 BM construction methods Labour enhancement
A5.3.7.10.3 Spreading the aggregate Use labour enhancement for all BM layer
A5.3.7.10.4 Initial compaction Required for all BM layers
Adding fine aggregate and dry

A5.3.7.10.5 Required for DBM, PPM and SBM
rolling
A5.3.7.10.6 Wet rolling and slushing Required for WBM
A5.3.7.10.7 Surface finish of BM layer As per the Contract Documentation and Chapter 10 : Surface Treatments
‘Rondavel’ test 84 % to 86 % of apparent density (AD) for all DBM

A5.3.8.3
(NITRR Technical Note TP/52/83) 88 % to 90 % of AD for all WBM
During the construction of the trial section the aspects of these Clauses shall be validated and modified where necessary. Any resultant
modifications of these Clauses shall then be implemented during the subsequent construction of the BM pavement layer.
This trial section shall be constructed where it can be trafficked and monitored during the course of the project. The location of the trial section
shall be as detailed in the Contract Documentation and could form part of the pavement for the deviation. The BM shall be constructed with edge
restraints and on a subbase with the same specification as for the pavement design for the works. The performance of the layer in the trial section
shall be assessed prior to acceptance thereof and use in the main works.
The trial section shall also be used to establish or verify the following aspects:
• The loose to tight compaction factors for the coarse aggregate.
• The loose volume of fine aggregate required per cubic metre of completed layer.
• The loose depth of coarse aggregate required to provide the specified final layer thickness.
• To establish or verify construction techniques, tools and procedures that will achieve the maximum possible density and produce the specified
surface finish.
• To confirm the average density achieved by means of the ‘Rondavel’ test (Clause A5.3.8.3).
• To establish the optimum time to prime.

Work in restricted areas is specified in Clauses A1.1.3.2 and A1.2.3.23 of Chapter 1.
Spreading material in restricted areas shall be done in such a manner that the required level and grading standards can be attained. Suitable equipment
and methods shall be used in restricted areas so that the required densities are obtained throughout the thickness of the layer. Where the compaction
apparatus used is of such a nature that the material in thicker layers cannot be properly compacted, the Engineer shall instruct that material be placed
and compacted in layers of as thin as 75 mm.
The Engineer may, in restricted areas, permit the contractor to spread, water and mix the gravel or crushed stone in a windrow next to the pavement
excavation. The existing surfacing shall not be damaged and the mixed material shall not be mixed with any deleterious material. Where this method
of mixing is impractical or impossible and mixing on adjacent surfaces is not permitted, mixing shall be done in a central mixing plant or in the case
of small quantities, suitable portable concrete mixers may be used.
Irrespective of the layer concerned, the mixing shall be of such quality that a uniform mix shall be obtained.
Where any construction work is being done adjacent to an existing surfacing, the existing surfacing shall not be damaged.
A5.3.8 WORKMANSHIP

Compaction testing shall be done within 24 hours of the layer being constructed.

The test results and measurements shall be assessed in accordance with the provisions of Chapter 20: Quality Assurance.
All damage done to a completed layer during any testing procedure shall be repaired and made good as instructed by the Engineer at no cost to
the Employer.
A5.3.8.3 Bound macadam (BM) layer compaction requirements

The density of the completed BM layer shall be tested using the ‘Rondavel’ test described in NITRR Technical Note TP/52/83. Density tests shall
be carried out at a frequency of approximately one test per 50 m3 of compacted BM layer.
In addition, a proof rolling test shall be carried out to establish if there is any audible grinding of the coarse aggregate or visible movement in the
layer as the roller passes over. Audible grinding indicates that full interlock of the stone has not been achieved, nor has maximum density been
attained. Additional ‘Rondavel’ tests shall then be done to further investigate any suspect areas detected during this inspection.
The density requirements shall be deemed to have been satisfied provided that the test results of the section tested exceed the apparent density
(AD) as achieved in the successful trial section.
A5.3.8.4 Construction tolerances for pavement layers

The values specified below apply to a layer thickness of 150 mm or more. For layers with a thickness less than 150 mm, more stringent tolerance
values may be specified in the Contract Documentation.
a) Level tolerances
For all layers the level tolerances referred to in Chapter 20: Quality Assurance shall be as given in Table A5.3.8-1.
Table A5.3.8-1: Pavement layer level tolerances (H = road elevation)
Layer H90 Hmax
Selected layer 25 mm 33 mm
Subbase layer 15 mm 20 mm
Crushed stone or gravel 12 mm 15 mm

Base layer
Bound macadam 20 mm 25 mm
Shoulder and wearing course layer n/a 25 mm
Level control for the different pavement layers shall be done at the following intervals given in Table A5.3.8-2:
Table A5.3.8-2: Pavement layer level control intervals
Layer Longitudinal interval Transverse interval
Selected, sub-base, shoulder and wearing course Centre-line, yellow line and outer edges plus at
20 m
layers intermediate mid-points
Centre-line, yellow line and outer edges plus at

Crushed stone or gravel 10 m
intermediate mid-points
Base layer
Centre-line, yellow line and outer edges plus at
Bound macadam 10 m
intermediate mid-points
b) Layer thickness tolerances

The thickness tolerances referred to in Chapter 20: Quality Assurance shall be as given in Table A5.3.8-3. Layer thicknesses shall be established
from the difference in actual levels taken on the preceding layer, and not from the design levels, and levels taken on the layer under consideration.
Table A5.3.8-3: Pavement layer thickness tolerances (D = layer depth or thickness)
Layer D90 Dmax Dave
Selected layer 25 mm 35 mm 8,0 mm
Subbase layer 18 mm 24 mm 5,0 mm
Base layer 15 mm 22 mm 5,0 mm
Shoulders and wearing course layer None 30 mm 0 mm
Bound macadam layer 21 mm 27 mm 5,0 mm
c) Grade tolerances
Deviations from the specified longitudinal grade shall not exceed the values given in Table A5.3.8-4 in respect of the specified grades on the
completed base. These allowable deviations are also valid for BM base layers:

Table A5.3.8-4: Pavement layer grade tolerances
Length (𝒍) of section under review (m) Maximum deviation (g) of specified slope (%)
2 0,354 %
5 0,224 %
10 0,158 %
20 0,112 %
30 0,091 %
The following formula shall be applicable for any other lengths (ℓ) over which the grade deviations may be calculated:
𝟎. 𝟓
𝒈(%) =
√𝒍
d) Width tolerances
The average width of the layer shall not be less than the specified width, and nowhere shall the outer edge deviate by more than the measurement
shown in Table A5.3.8-5 from the designed road edge lines shown in the Contract Documentation:
Table A5.3.8-5: Pavement layer width tolerances
Layer Maximum deviation from designed edge lines
Selected layer 80 mm
Subbase layer 75 mm
Base layer 50 mm
Shoulders and wearing course layer 75 mm
e) Cross-fall and cross-section regularity

When tested with a 3,0 m straightedge laid at right angles to the road centre line, the surface of any layer shall not deviate from the bottom of the
straightedge by more than 6,0 mm.
For BM base layers only, when a 3,0 m straight-edge is laid on the finished surface, the gap between the straightedge and the coarse aggregate
in the surface shall not at any point exceed 10 mm when placed either parallel or at right angles to the centreline of the road.
At any cross-section, the difference in level between any two points shall not vary from their difference in level computed from the cross-sections
shown on the drawings by more than 15 mm.
A5.3.8.5 Surface regularity

Surface regularity, or riding quality of the base layer, shall be assessed by one or more of the following methods as specified in the Contract
Documentation.
a) By using a 3,0 m straight-edge
A 3,0 m long straight-edge with sharp right-angled corners at the bottom as well as a tapered wedge, shall be used for measuring irregularities on
the base layer. The straight-edge shall be placed on the road and measurements taken by inserting the thin edge of the wedge below the straight-
edge. Measurements shall be done in each wheel path of each lane or shoulder randomly, at not more than 10 m apart.
The maximum value of an individual surface irregularity measured at any point with a 3,0 m straight-edge, shall not exceed 10 mm.
b) By using a rolling straight-edge
Before each day’s measurements are taken, the rolling straight-edge shall be calibrated.
For measuring the irregularities, measurements shall be done in each wheel path of each lane or shoulder over the full length of the section. The
number of surface irregularities shall not exceed those given below:
• The average number of irregularities per 100 m equal to or exceeding 5,0 mm when taken in wheel paths over 300 m to 600 m
lengths……………………………………………………………………………………………………………………………………………≤ 3
• The number of irregularities equal to or exceeding 5,0 mm when taken over 100 m lengths…………………………………… ≤4
The maximum deviation for each wheel path must also be recorded and shall not exceed 10 mm.
c) By using a profiler
An inertial laser profilometer or a Walking Profiler capable of producing a Class 1 vertical measurement resolution, and a Class 3 longitudinal
sampling distance as defined in ASTM standard (E950-09), shall be used to determine the roughness of the base layer in the case of ;
• newly constructed base layers; and
• where an existing base layer or part thereof (in depth) is rehabilitated by reconstruction or by recycling over the full width of a traffic lane or
on a shoulder that is wider than 2,0 m to be surfaced. Shoulders with a width of less than 2.0 m to be surfaced, shall be assessed according
to measurements obtained from the adjacent lane.

The profilers shall be furnished and operated by the Contractor in the presence of the Engineer. Prior to using an inertial laser profilometer, it
shall have successfully completed a validation trial against the Instrument of Reference used by the Employer.
The inertial laser profilometer or Class 1 Walking Profiler shall be used to record the longitudinal profile in both wheel tracks of each traffic lane or
shoulder wider than 2,0 m, as determined according to the final line/lane markings that will be applied on the road surface after completion of
construction. For the inertial laser profilometer, three repeated runs shall be carried out. For the Class 1 Walking Profiler only a single
measurement will be required per wheel track. The two wheel tracks shall be 1,75 m apart. Should the two wheel tracks not be measured
simultaneously during the same pass, then procedures shall be implemented to ensure that the longitudinal profile data recorded for the two wheel
tracks are at the same longitudinal location on the road.
The measured longitudinal profiles will then be processed using the Quarter-Car simulation model with parameter values as defined in ASTM
standard (E1170-97) for Ride Meter-Vehicle Mounted. The simulated suspension mentioned will then be linearly accumulated and divided by the
length to yield 100 m IRI (International Roughness Index) values in units of mm/m or m/km for each wheel track. The last 50 m and the joining
first 50 m of adjacent sections will be evaluated as a 100 m section in the direction of vehicle travel. Where the works is of such a nature that
public traffic needs to cross the constructed base layer to gain access to and from adjacent properties, the Contractor shall identify these positions
beforehand. A width of minimum 10 m and maximum 20 m may be identified for each access / crossing. The IRI values for each of these sections
shall be excluded from the individual 100 m section values being evaluated.
For inertial laser profilometer measurements the left and the right 100 m IRI values from the three runs for each measured lane will then be
averaged to produce the average IRI as follows:
Run1 IRI100 m ave = (100 m IRILeft wheel track + 100 m IRIRight Wheel track) / 2
Average IRI100m = (Run1 IRI100 m Ave + Run2 IRI100 m Ave + Run3 IRI100 m Ave) / 3
For the Class 1 Walking Profiler measurements, the Average IRI will be calculated as follows:
Average IRI100 m = (100 m IRILeft wheel track + 100 m IRIRight Wheel track) / 2
The Average IRI100 m values shall then be evaluated and judged according to Table A5.3.8-6 to determine whether the 100 m section needs
corrective work or payment adjustments.
Table A5.3.8-6: Payment adjustment for base layer
Payment adjustment factor
Average
IRI100 m (m/km) Reworked or Recycle existing layers New pavement
Recycled Base and new base layer construction
<1.50 1.050 1.050 1.050

1.51 to 1.60 1.050 1.050 1.025
1.61 to 1.70 1.050 1.050 1.010
1.71 to 1.80 1.050 1.050 1.000
1.81 to 1.90 1.050 1.025 0,990
1.91 to 2.00 1.050 1.010 0,975
2.01 to 2.10 1.050 1.000 0,955
2.11 to 2.20 1.025 0,990 0,930
2.21 to 2.30 1.010 0,975 0,900
2.31 to 2.40 1.000 0,955 0.865
2.41 to 2.50 0,990 0,930 Reject
2.51 to 2.60 0,975 0,900 Reject
2.61 to 2.70 0,955 0.865 Reject
2.71 to 2.80 0,930 Reject Reject
2.81 to 2.90 0,900 Reject Reject
2.91 to 3.00 0.865 Reject Reject
>3.01 Reject Reject Reject
Adjustment to the payment for the base will be reflected separately in the Contractor’s monthly certification of the works. The adjustment will be
calculated by multiplying the full payment value for each 100m section, for payment items *** _________________ by the payment adjustment
factor derived from Table A5.3.8-6. Contract Price Adjustment shall not be applicable to the payment adjustment for the base. The payment
adjustment shall apply to the total base layer width placed over the 100m section in question.
Surfaced shoulders less than 2,0 m wide will be assumed to have the same roughness measurements as the adjacent lane and the quantity of
material in the shoulder shall be added to the quantity of material of the adjacent lane for determination of the payment adjustment factor.
On sections where the Average IRI100 m is worse than the cut-off value listed in the Contract Documentation the section shall be rejected and
corrective work shall be necessary.
Any corrective work required shall be made by the removal of the total base layer width placed, over the 100 m section in question, followed by
reinstatement. Surfaced shoulders less than 2,0 m wide shall be treated the same as the adjacent slow lane. Corrective work shall not commence
until the Engineer has reviewed the Contractor’s method statement. If the Contractor proposes any other corrective procedure he shall apply to
the Engineer for the Employer’s approval of the proposal. Corrective work shall be done at no cost to the Employer and shall be completed prior
to determining the pavement thickness. After completion of the corrective work, the 100 m sections shall be re-evaluated according to the

specifications.
Where the base layer is surfaced with an asphalt surfacing subject to a surface regularity specification contained under Clause A9.1.8.4 of Chapter
9, the Contractor may choose to leave the base layer over the 100m section in question in place. In such an event, the maximum negative payment
adjustment factor obtained from Table A5.3.6-6 shall be applied to the section in question. The average IRI 100 m before the construction of the
asphalt surfacing (IRI b Ave) required to determine the target IRI for the asphalt surfacing as defined in Clause A9.1.8.4 of Chapter 9 shall be
determined for the section in question as follows:
Determine the base 100 m sections applicable to a lot (or section) of asphalt intended to be paved in one day’s production. Determine the 100 m
base section so identified with the highest achieved IRI value. This value will be used as the input value for the IRI b Ave for the section in question.
The longitudinal profile and the 100 m International Roughness Index (IRI) values shall be determined using an inertial laser profilometer or a
Class 1 Walking Profiler furnished and operated by the Contractor or on behalf of the Contractor in the presence of the Engineer. Prior to using
an inertial laser profilometer it shall have successfully completed a validation trial against the Instrument of Reference namely the Class 1 Walking
Profiler, used by the Employer.
As an absolute minimum the longitudinal profile shall be measured as soon as a 2000 m section of lane or shoulder is completed. Where shorter
than 2000 m sections of a layer is required to be constructed the section as a whole will be measured as soon as it is completed. The contractor
shall be paid for these measurements under payment item B81.05. No additional payment will be made to the Contractor for additional
measurement and analysis of profiles when ordered by the Contractor for own assessment purposes, or if additional surveys are required as a
result of any remedial / corrective work identified and subsequently completed.
For new base layers and rehabilitation of existing base layers where the layer or part thereof (in depth) is required to be reworked or recycled over
a length of less than 600 m and over the full width of a traffic lane or shoulder the roughness of the layer will be determined by using a Class 1
Walking Profiler.
The raw measurements from the inertial laser profilometer or Walking Profiler will be uploaded to SANRAL through the SARDS Quality Assurance
module.
(***Note to compiler: Insert the relevant base layer construction pay items but exclude pay items for additives such as cement and bitumen)

B5.3 ROAD PAVEMENT LAYERS
B5.3.1 SCOPE
B5.3.2 DEFINITIONS
B5.3.3 GENERAL
B5.3.5 MATERIALS
B5.3.8 WORKMANSHIP
B5.3.1 SCOPE
This Section covers the preparation of the roadbed/subgrade on an existing alignment, the construction of selected subgrade layers (where
applicable), subbase, bases (unstabilised and treated/stabilised in accordance with Section A5.4: Stabilisation), wearing courses and shoulders
with natural and crushed gravel using labour enhanced methods of construction and light plant.
Material for the road pavement layers is produced as specified in the relevant Sections of Chapter 4.
The addition and mixing of stabilising agents either as an integral part of the PMPL process or for some of the conventionally placed road pavement
layers that require treatment and/or stabilisation is specified in Section A5.4.
The reconstruction of existing road pavement layers is specified in Section A5.5.
B5.3.2 DEFINITIONS
Definitions as provided in Clause A5.3.2 apply.
B5.3.3 GENERAL
The relevant specifications of A5.3.3 of Part A shall be applicable.
B5.3.4 DESIGN BY THE CONTRACTOR/PERFORMANCE BASED SYSTEMS

B5.3.5 MATERIALS
B5.3.5.1 Material information

The required material properties for each individual pavement layer for a specific pavement design shall be clearly specified in the Contract
Documentation.
B5.3.5.2 Pavement layer thickness and compaction requirements

a) Pavement layer thickness requirements
The compacted pavement layer thickness shall be as specified in the Contract Documentation. Layer thicknesses of layers constructed using
labour enhanced methods of construction shall be restricted to maximum of 100 mm.
The thickness tolerances specified in Clause A5.3.8.4b) shall apply.
b) Gravel and soil pavement layer compaction requirements (G4B to G9 material)

The compacted dry density of a gravel or soil pavement layer shall be as specified in Table A5.3.5-1 unless specified otherwise in the Contract
Documentation shall apply.
Where no density specification is specified for layers constructed by labour and light plant, the integrity and workmanship of each trail section
shall be assessed by Dynamic Cone Penetrometer (DCP) and shall comply with the following in situ readings:
The average of 4 DCP readings randomly chosen to cover the entire trial section and expressed in mm/blow, shall not exceed the following figures:

• Gravel Base/Wearing course -4
• Gravel Subbase layer -9
• Gravel Upper Subgrade - 18
• Gravel Lower Subgrade - 25

Construction equipment to carry out the construction of the pavement layers shall comply with the requirements of Clause A1.2.6 of Chapter 1.
The following specialised plant and equipment shall be used to promote the construction of the layer with labour enhancement:
• Suitably sized (approximately 1 ton) tandem vibratory pedestrian rollers having two equally sized drums in tandem - both drums driven, each
drum to have a separate eccentric shaft
• Steel angle formwork (shutters), 150 mm x 100 mm x 6,0 mm thick (1 m, 2 m and 3 m lengths)
• Steel spacer plates (bulking rails), 75 mm x 6,0 mm and 50 mm x 6,0 mm capable of slotting onto the steel angle formwork to form a
continuous shutter for levelling the loose material (1 m, 2 m and 3 m lengths)
• 75 mm x 75 mm and 50 mm x 50 mm steel box sections for tying in levels of new work with previously constructed work (1 m, 2 m, and 3 m
lengths)
• Steel squeegees
• Screeding boards comprising steel or aluminum straight edge of suitable length for screeding loose material
• Plastic sheeting
• Cross fall templates of 2 % or 3 % as specified
• Steel pegs of various lengths (Y10)
• String or sisal, 3,0 mm white
• Water tank on LDV or mounted on trailer with pump, 1000 litres
• Wheelbarrows
• Shovels
• Brooms
• Steel tape, 50 m

B5.3.7.1 Controlling pavement layer thickness
Steel side forms shall be used during the placing and spreading of the pavement layer material. The steel angle formwork shall have dimensions
conforming to 150 mm x 100 mm x 6,0 mm thick and be available in 3 m, 2 m and 1 m lengths or as specified in the Contract Documentation. The
shorter lengths of angle formwork are for use with smaller radius curves.
Sufficient steel forms for one day's work shall be available.
All material placed in position before compaction shall be spread evenly over the entire surface of the layer concerned and the quantity of material
spread shall be such that every layer will comply with the requirements for thickness as specified in the Contract Documentation, when measured
after compaction.
The Contractor shall ensure that segregation of the material into finer and coarser fractions does not occur in any of the stockpiling, loading,
hauling, spreading and subsequent mixing operations.
B5.3.7.2 Mechanical modification of pavement layer material

The relevant specifications of A5.3.7.2 of Part A shall be applicable.
B5.3.7.3 Construction of gravel pavement layers

a) Construction
All material to be used for the construction of gravel pavement layers shall be checked at the source of supply for compliance with the material
properties specified in Chapter 4 before being loaded and hauled to the road construction area or to the central mixing plant.
Oversize material up to a maximum of 5 % by compacted volume can be hauled to the point of use on the road or to the central mixing plant. The
oversize material shall then be removed by hand on the road and then loaded and hauled to a spoil site.
The distance over which the material is to be carted from the gravel heaps to be placed on the road shall be minimised.
To facilitate the achievement of this objective where material is hauled by trucks from borrow pits to the work area, it should be strived to use
trucks of the same measured and known capacity (e.g. 6 m3, 7 m3 or 10 m3, etc.).
The spacing of the gravel heaps delivered by the truck/s shall be established by the Contractor calculations, based on the loose thickness to which
the material shall be placed.
The spacing of each truck load shall be demarcated and controlled by means of markers on the surface of the road.
b) Construction with labour enhancement
The day before spreading and mixing the dumped material, the heaps shall be dampened.
The heaped gravel material shall be brought to and maintained at optimum moisture content (OMC) immediately prior to placement on the road,
and the material shall be protected against drying out during the construction process using plastic sheets.

(i) Placing of steel side forms (shutters)
Care shall be taken when fixing the steel formwork to ensure that no bumps are built into the surface and that a smooth vertical
and horizontal alignment is obtained.
The steel formwork shall be firmly and correctly placed so as to comply with the specified dimensions, lines and levels of the road
or section to be constructed,
Once the steel side forms have been placed, the levels shall again be checked (by string lining across the tops of the side forms)
and the surfaced trimmed to ensure that the correct thickness of pavement layer is laid.
(ii) Placing of the layer
Before placing the layer, the lower layer shall be lightly watered.
The material for the layer being constructed shall be wheelbarrow placed between the steel side forms at a uniform spacing to
achieve a minimum amount of material relocation when the loose material is screeded/levelled to the required depth of 1,5 times
the compacted depth.
Calculation of the spacing of the wheelbarrow loads shall be done by the Contractor.
A steel spacer plate (bulking rail) shall be placed on top of the 150 mm or 100 mm flange of the steel side forms to obtain a height
of 225 mm or 150 mm (depending on the required compacted thickness of the layer – 100 mm or 150 mm. Using the steel
squeegees and steel screed bar the material shall be spread level with the top of the spacer plate to obtain a 225 mm or 150 mm
thick loose layer. No pedestrian traffic shall be allowed onto the loose layer before screening or compaction.
Where the layer is constructed adjacent to previously constructed work a suitably sized spacer shall be placed on top of the
existing work to obtain the correct loose thickness for the new work.
When using coarse material over-sized fractions shall be removed from the surface and replaced with finer material to achieve
the required smooth finish.
A plastic sheet shall be rolled out over the layer as the work progresses in order to inhibit the material drying out.
(iii) Compaction of the layer
Once 8,0 m to 10,0 m in length of the layer has been completed, the plastic sheet may be rolled up and compaction may
commence.
Compaction with an approved pedestrian roller in vibratory mode shall be executed until the loose layer, as determined by the
spacer plate, has been compacted to the top edge of the vertical flange of the steel side form.
Rolling shall commence at a 45o angle to the edge line of the shutters and shall thereafter continue in such a manner that the
roller is always supported over approximately a half of its width initially either on an existing surface or the steel side forms.
Compaction shall be done in vibratory mode, parallel to the shutter lines, moving from both sides inward towards the middle of
the layer in increments of slightly less than half the width of the roller, after each pass of the roller.
B5.3.7.5 Construction of gravel shoulder

The construction of gravel shoulders using labour enhancement shall be constructed as specified in Clause B5.3.7.3a) and b).
B5.3.7.6 Construction of composite bound macadam (BM) layers

The recommended layer thickness for a composite bound macadam layer, constructed using labour enhancement is limited to 100 mm. The
bottom part is constructed as either a water-bound or a dry-bound macadam. The maximum thickness of the bottom part is 70 mm if light pedestrian
compactors are used. Light pedestrian walk behind rollers can be used to compact and orientate the bottom part of the coarse aggregate prior to
the application of the filler sand. The light vibratory pedestrian rollers may also be used to vibrate the filler sand into the voids. If a thicker layer is
constructed, the density specification as per Part A will still apply which implies the use of heavier rollers.
The upper part shall be a slurry bound macadam layer done in accordance with specifications in Chapter 10.
B5.3.7.7 Construction of trial sections

The trial section shall demonstrate the capability of the Contractor to construct the pavement layer in accordance with the specification using
labour enhancement.
The trial section shall be constructed with the same materials and equipment as those intended for use by the Contractor for the final pavement
layer in the works.
An eight-metre long trial section shall be constructed on a suitably prepared and located position as directed by the Engineer for compliance to
the specification. Only once approved by the Engineer may the Contractor proceed to construct the specific layer in its proper location on the road
under construction.
A compliant trial section shall be reimbursed only when it complies with all the requirements of the specification and has been accepted. The
mixing process and equipment shall remain unaltered for all subsequent layer construction for which the trial section was constructed, unless
otherwise instructed by the Engineer.
If after acceptance of the trial section, the Contractor
• changes the method of construction, or
• changes the construction equipment, or
• changes the materials, or
• changes the mix used, or
• changes the rate of paving for the construction of the layers in the works, or
• the Contractor has difficulty in attaining the specified level of workmanship;

then the Engineer may instruct that a new trial section be constructed.
B5.3.8 WORKMANSHIP
B5.3.8.1 Inspection of the works

C5.3 ROAD PAVEMENT LAYERS
(i) Preamble
otherwise stated.
deemed appropriate:
1. All surveying, setting out and level control required for the construction of the pavement layers.
2. Drainage and protection of the pavement layers from all damage that may occur for any reason until the Employer has taken over the works.
3. Protection of all existing or new kerbs, channels, sidewalks, lined drains, catch pits, kerb inlets, gratings, culverts, bridges, structures,
buildings, road signs, guard rails, street lights, fencing, service pipes or cables and any other items adjacent to, over or under the road that
could be damaged by the Contractor’s vehicles, construction equipment, or by public traffic being accommodated on or alongside the
pavement layers, during the construction of the pavement layers, until the Employer has taken over the works.
4. Compaction immediately adjacent to existing or new kerbs, channels, sidewalks, lined drains, catch pits, kerb inlets, gratings, culverts,
bridges, structures, buildings, road signs, guard rails, street lights, fencing, service pipes or cables etc. using hand operated compaction
equipment.
5. Repair of all damage to the pavement layers and any new or existing structures, buildings, road furniture and services that may occur for any
reason before, during or after the construction of the pavement layers up until the Employer has taken over the works.
6. Provision of additional material in excess of the compacted volume of the layers calculated using the layer dimensions given in the Contract
layers.
7. Removal of additional material required for the correct mixing and working of the layers and left in windrow or on the sides of the road.
8. Breaking down and removal of oversize material up to 5 % of the compacted layer volume. Payment will only be made to remove any oversize
material in excess of 5 % of the compacted layer volume that cannot be broken down on the road when instructed by the Engineer.
9. Loading and hauling of commercial pavement material identified by the Employer or by the Contractor.
10. Loading and hauling of alternative material identified by the Contractor.
11. Construction of tie-in joints to new or existing road layers or surfacing.
(iii) Items to be measured and paid for using payment items specified elsewhere in the specifications
Loading and hauling A5.3.1
applicable items
Stabilisation A5.3.1
applicable items
Subsoil drainage A5.3.3.8
applicable items
Asphalt base layer A5.3.7.5
applicable items
Bound macadam surfacing A5.3.7.10g) C10.1.2 of Chapter 10
Construction of edge constraints for BM A5.3.7.10a)
applicable items
Priming A5.3.3.9 / 10 Chapter 10 – All applicable items
Screening material A5.4.7.2d)
applicable items
Emulsion slurry Table A5.3.5-4
applicable items

C5.3.1 Compiling and implementing M&U plans for the construction of all the pavement layers number (no)
The unit of measurement shall be the number of compiled M&U plans for the construction of the pavement layers.
Usually only one plan shall be required for each of the layers unless specified otherwise in the Contract Documentation.
The tendered rate shall include full compensation for gathering all information and compiling the plan(s) and for ensuring the implementation of
the plan(s) during the construction of the pavement layers.
C5.3.2 Construction of pavement layers
C5.3.2.1 Construction of layers using conventional construction methods:
(a) Lower selected subgrade layer (layer thickness indicated) compacted to 93 % of MDD cubic metre (m3)
(b) Lower selected subgrade layer (layer thickness indicated) compacted to 95 % of MDD cubic metre (m3)
(c) Upper selected subgrade layer (layer thickness indicated) compacted to 95 % of MDD cubic metre (m3)
(d) Upper selected subgrade layer (layer thickness indicated) compacted to 97 % of MDD cubic metre (m3)
(e) Sand layer (layer thickness indicated) compacted to 97 % of MDD cubic metre (m3)
(f) Sand layer (layer thickness indicated) compacted to 100 % of MDD cubic metre (m3)
(g) Gravel wearing course layer (layer thickness indicated) compacted to 95 % of MDD cubic metre (m3)
(h) Gravel shoulder layer (layer thickness indicated) compacted to 95 % of MDD cubic metre (m3)
(i) Lower subbase gravel layer (unstabilised) (layer thickness indicated) compacted to 95 % of cubic metre (m3)
MDD
(j) Lower subbase gravel layer (chemically stabilised) (layer thickness indicated) compacted to cubic metre (m3)
95 % of MDD
(k) Upper subbase gravel layer (unstabilised), (layer thickness indicated) compacted to 97 % of cubic metre (m3)
MDD
(l) Upper subbase gravel layer (chemically stabilised), (layer thickness indicated) compacted to cubic metre (m3)
95 % of MDD
(m) Gravel base layer (unstabilised), (layer thickness indicated) compacted to 100 % of MDD cubic metre (m3)
(n) Gravel base layer (chemically stabilised), (layer thickness indicated) compacted to 97 % of cubic metre (m3)
MDD
(o) G5B crushed rock/boulder subbase layer (layer thickness indicated) compacted to 97 % of cubic metre (m3)
MDD
(p) G5B crushed rock/boulder base layer (layer thickness indicated) compacted to 100 % of MDD cubic metre (m3)
(q) G5A crushed rock/boulder subbase layer (layer thickness indicated) compacted to 97 % of cubic metre (m3)
MDD
(r) G5A crushed rock/boulder base layer (layer thickness indicated) compacted to 100 % of MDD cubic metre (m3)
(s) G4A crushed rock/boulder lower subbase layer (unstabilised or chemically stabilised) (layer cubic metre (m3)
thickness indicated) compacted to 95 % of MDD
(t) G4A crushed rock/boulder upper subbase layer (unstabilised or chemically stabilised) (layer cubic metre (m3)
thickness indicated) compacted to 97 % of MDD
(u) G4A crushed rock/boulder subbase layer compacted to 97 % of MDD cubic metre (m3)
(v) G3 crushed stone subbase layer (unstabilised or chemically stabilised) (layer thickness cubic metre (m3)
indicated) compacted to 97 % of MDD
(w) G3 crushed stone base layer (layer thickness indicated) compacted to 85 % of BD cubic metre (m3)
(x) G2 crushed stone base layer (layer thickness indicated) compacted to 88 % of BD cubic metre (m3)
(y) G2 crushed stone base layer (layer thickness indicated) compacted to 88 % of AD cubic metre (m3)
(z) G1 crushed stone base layer (layer thickness indicated) compacted to 86 % of AD cubic metre (m3)
(aa) G1 crushed stone base layer (layer thickness indicated) compacted to 88 % of AD cubic metre (m3)
(bb) Bound macadam layer (layer thickness indicated) compacted to 90 % of AD cubic metre (m3)
(cc) PMPL wet lean-mix concrete layer (Cube crushing strength and layer thickness indicated) cubic metre (m3)
C5.3.2.2 Construction of layers using labour enhancement:
(a) Lower selected subgrade layer (layer thickness indicated) compacted to 93 % of MDD cubic metre (m3)
(b) Upper selected subgrade layer (layer thickness indicated) compacted to 95 % of MDD cubic metre (m3)
(c) Sand layer (layer thickness indicated) compacted to 97 % of MDD cubic metre (m3)

(d) Sand layer (layer thickness indicated) compacted to 100 % of MDD cubic metre (m3)
(e) Gravel wearing course layer (layer thickness indicated) compacted to 95 % of MDD cubic metre (m3)
(f) Gravel shoulder layer (layer thickness indicated) compacted to 95 % of MDD cubic metre (m3)
(g) Lower gravel subbase layer (layer thickness indicated) compacted to 95 % of MDD cubic metre (m3)
(h) Upper gravel subbase layer (layer thickness indicated) compacted to 97 % of MDD cubic metre (m3)
(i) Gravel base layer (layer thickness indicated) compacted to 98 % of MDD cubic metre (m3)
(j) Gravel base layer (layer thickness indicated) compacted to 100 % of MDD cubic metre (m3)
(k) Bound macadam layer (layer thickness indicated) compacted to 90 % of AD cubic metre (m3)
(l) Soil cement or soilcrete (layer thickness indicated) wet mixture as per clause A4.1.5.14 cubic metre (m3)
(m) Soil cement or soilcrete (layer thickness indicated) stiff mixture as per clause A4.1.5.14 cubic metre (m3)
(n) Emulsion treated base material (G1 or G2 material and layer thickness indicated) as per clause cubic metre (m3)
A4.1.5.15
The unit of measurement shall be the cubic metre of material in the compacted layer, calculated using the layer work dimensions given in the
The tendered rates shall include full compensation for spreading the material, for breaking down oversize gravel material using one normal grid
rolling operation or an equivalent operation, for removal of up to 5 % of the compacted layer volume of oversize material that cannot be broken
down, for adding water for compaction purposes, for mixing, for levelling, for compacting to the specified density, for slush-compaction of G1
material layers or other layer that may be specified to receive slush-compaction and for finishing the layers in accordance with the specifications
and the Contract Documentation. The tendered rates shall also include for the removal of all material in the windrow after the compaction of the
layer has been completed.
Measurement and payment for loading the layer work material from borrow pits, quarries, cuttings, reclaimed material from existing roads and
alternative materials identified by the Employer, transporting and then off-loading the material at the point of use is made under items C1.7.1 and
C1.7.2 of Chapter 1.
The haul of the imported material shall be measured from the point of loading/collection to the point of off-loading as per Section A1.7 of Chapter
1.
A distinction shall be made between construction using conventional construction methods and labour enhancement.
C5.3.3 Construction of crushed stone base supplied by the Employer cubic metre (m3)
This item is for crushed stone base constructed from type G1 or G2 material supplied from the Employer’s stockpile (state location of stockpile)
at R………………….. per ton (layer thickness indicated) and compacted to 88 % AD or 86% AD respectively as specified in the Contract
Documentation.
The unit of measurement shall be the cubic metre of completed crushed-stone base in-situ and compacted to the specified density. The quantity
shall be calculated from the net authorised dimensions of the layer as shown on the drawings or prescribed by the engineer. No adjustments shall
be made to the net specified dimensions for level and thickness tolerances, overbuilding and/or other wastage.
The tendered rate shall include compensation for the purchase of the material from the Employer at R.......................per ton, weighing on the
calibrated weighbridge, furnishing and placing all materials, including crusher fines for correcting the grading of the crushed-stone and hauling the
material to the point of use, rolling slushing and correcting the layers, and for testing, protecting and maintaining the work all as specified.
C5.3.4 Deductions for G1 crushed stone base material supplied by the Employer ton (t)
The unit of measurement shall be the ton of material supplied by the Employer.
The value of material supplied by the Employer and to be deducted from payments due to the contractor, shall be determined as the sum of
audited weighbridge documentation and delivery notes.
C5.3.5 Breaking down oversize gravel layer material on the road
C5.3.5.1 By additional normal grid rolling as per clause A5.3.7.3b) square metre-pass (m2-pass)
C5.3.5.2 By tamping roller square metre-pass (m2-pass)
C5.3.5.3 By pad foot vibratory roller square metre-pass (m2-pass)
C5.3.5.4 By vibratory roller square metre-pass (m2-pass)
C5.3.5.5 By any other roller type square metre-pass (m2-pass)
The unit of measurement shall be the square metre-pass calculated by multiplying the layer surface area covered by the agreed number of roller-
passes used to break down the material satisfactorily.
The tendered rate for each square metre-pass instructed by the Engineer shall include full compensation for all supervision, labour, equipment,
fuel, materials, work and incidentals necessary for completing the work. The same rates shall be applicable should there be a reduction in the
number of roller-passes for a specific type of roller.

The tendered rate shall include full compensation for supplying the roller and removing the roller after completion of the breaking down process.
The items shall differentiate between the different types of rollers used.
C5.3.6 Removal of oversize material cubic metre (m3)
The unit of measurement shall be the cubic metre of oversize material which cannot be broken down on the road and is removed for re-crushing
or removed to spoil as instructed by the Engineer in excess of the 5 % of the compacted layer volume of oversize material included in the rates
tendered for item C5.3.2.
The volume measured for payment shall be taken as 70 % of the loose volume in excess of 5 % of the measured volume of the layer as measured
in the haul vehicles.
The tendered rate shall include full compensation for removing the oversize material from the pavement layers, loading it into the hauling vehicles
and off-loading it at the point of disposal.
The haul of the oversize material in excess of 5 % by volume per layer shall be measured from the point of loading/collection to the point of off-
C5.3.7 Recombining recovered material cubic metre (m3)
The unit of measurement shall be the cubic metre of the recombined material added to and mixed into the pavement layer as specified in Clause
A5.3.7.2. The volume measured for payment shall be taken as 70 % of the loose volume of recovered material as measured in the haul vehicles.
The tendered rate shall include full compensation for mixing the recombined recovered material binder into the layer to form one homogeneous
layer.
Payment for the construction operations required to process and compact the recombined layer will be paid for under item C5.3.2 and other
relevant items
The haul of the recovered material shall be measured from the point of loading/collection to the point of off-loading as per Section A1.7 of Chapter
1.
C5.3.8 Processing of coarse gravel subbase or base layers cubic metre (m3)
The unit of measurement shall be the cubic metre of material in the compacted layer calculated using the layer work dimensions given in the
The tendered rate shall include full compensation for carrying out the processing and finishing work for a coarse layer as specified in Clause
A5.3.7.4.
C5.3.9 Construction of a trial section
C5.3.9.1 Construction of a trial section using conventional methods of construction
(a) Stabilised gravel layer (layer thickness indicated) trial section cubic metre (m3)
(b) Crushed stone subbase layer (layer thickness indicated) trial section cubic metre (m3)
(c) Crushed stone base layer (layer thickness indicated) trial section cubic metre (m3)
(d) PMPL layer (layer thickness indicated) trial section cubic metre (m3)
(e) Bound macadam layer (layer thickness indicated) trial section cubic metre (m3)
(f) Any other cubic metre (m3)
C5.3.9.2 Construction of a trial section using labour enhancement methods
(a) Stabilised gravel layer (layer thickness indicated) trial section cubic metre (m3)
(b) Gravel base layer (layer thickness indicated) trial section cubic metre (m3)
(c) Bound macadam layer (layer thickness indicated) trial section cubic metre (m3)
(d) Any other cubic metre (m3)
The unit of measurement shall be the cubic metre of layer trial section constructed, tested and accepted. The quantity shall be calculated based
on the authorised dimensions of the trial section layer.
The tendered rate shall include full compensation for providing all the material and constructing the particular layer for the trial section as specified.
The tendered rate shall also include for any costs associated with a delay up to a maximum of ten working days, to allow for testing between
completion of the trial section and the acceptance thereof.
A distinction shall be made between construction using conventional construction and labour enhancement.

C5.3.10 Removal of a completed trial section
C5.3.10.1 Stabilised layer cubic metre (m3)
C5.3.10.2 PMPL layer cubic metre (m3)
C5.3.10.3 Crushed stone layer cubic metre (m3)
The unit of measurement shall be the cubic metre of compliant trial section layer removed to a designated site when instructed by the Engineer.
The tendered rates shall include full compensation for breaking up the trial section layer and for loading the broken up layer material..
The haul of the material to the designated site as instructed by the Engineer and off-loading the material shall be measured from the point of
loading/collection at the trial section to the point of off-loading as per Section A1.7 of Chapter 1.
The removal to spoil of a non-compliant trial section layer shall be done by the Contractor at no cost to the Employer.
C5.3.11 Riding quality measurements
C5.3.11.1 Using a 3,0 m straight edge kilometre (km)
C5.3.11.2 Using a rolling straight edge kilometre (km)
C5.3.11.3 Using an inertial profilometer kilometre (km)
The unit of measurement shall be the kilometre of riding quality measurements taken in each wheel path, measured along the wheel path as
specified in Clause A5.3.8.5.
The tendered rates shall include full compensation for the cost of all traffic accommodation arrangements required, for several possible
establishments and de-establishments of testing equipment, for the measurement of the riding quality with the specified instrument and the
processing, analysis and interpretation of the riding quality measurements.
C5.3.12 Surface regularity payment adjustments Provisional Sum (Prov Sum)
The unit of measurement shall be the cumulative monetary value of each 100 m section of the completed base layer as measured and
paid under item C5.3.2, multiplied by the applicable payment adjustment factor obtained from Table A5.3.8-6.

D5.3 ROAD PAVEMENT LAYERS
CONTENTS
D5.3.1 SCOPE
D5.3.2 GENERAL

5.4 STABILISATION
CONTENTS
A5.4.1 SCOPE
A5.4.2 DEFINITIONS
A5.4.3 GENERAL
A5.4.5 MATERIALS
A5.4.8 WORKMANSHIP

A5.4 STABILISATION
A5.4.1 SCOPE
This Section covers the work requirements for the treatment of the material properties of natural roadbed, fill layers or pavement layers and
crushed material by stabilisation, all in terms of the definition of Stabilisation in Clause A4.4.2 of Chapter 4.
A5.4.2 DEFINITIONS
The relevant definitions in the standard specifications are applicable. Additional definitions for this Section are included here.
Mechanical modification - mechanical modification, also referred to as granular stabilisation, is a form of stabilisation as defined in Clause A4.4.2
of Chapter 4. Mechanical modification of a pavement layer involves the addition and mixing together of various materials from different sources
to produce a uniformly mixed material that is compliant with the properties required for the pavement layer for which the modified material is being
used.
Lamination layer - a term used to describe the layer formed when a compacted layer delaminates and forms loose and unbonded layers on top
of the layer when incorrect compaction techniques are used. A colloquial term, biscuit layer, is also used for the lamination layers.
Breaking of emulsion - this term describes the process that occurs when the suspended bitumen in the emulsion separates from the water and
the water evaporates, leaving behind bitumen. It is also referred to as the setting of the emulsion.
Filler a filler is a commercially available product. A filler is often a cementitious agent. The quantity added is sufficient to result in improvement of
the properties of the material it is added to, but insufficient to result in the stabilisation of the material should the filler have been added in isolation.
A5.4.3 GENERAL
A5.4.3.1 Stabilisation agents
The type and quantity of cementitious or bituminous stabilisation agent to be used for each layer of material shall be determined as described in
Clauses A4.4.7.1c) and A4.4.7.1d) of Chapter 4.
The different types of cementitious and stabilisation agents are specified in Clauses A4.4.5.2, A4.4.5.3 and A4.4.5.4 respectively of Chapter 4.
Should a non-traditional stabilising or soil treatment agent be proposed by the Contractor, it will only be considered if the requested details specified
in Clause 4.4.5.4 of Chapter 4 are provided.

Work in restricted areas is specified in Clauses A1.1.3.2 and A1.2.3.23 of Chapter 1.
Where pavement layers are to be treated or stabilised in restricted areas such as widenings, no cementitious or bituminous agent may be spread
or mixed beyond the required width. The Contractor shall not be permitted to mix the material being stabilised on an adjacent paved surface.
Where restricted areas are such that mixing in the restricted area is impractical and mixing on adjacent surfaces is not permitted, mixing shall be
done in a central mixing plant. In the case of small quantities, suitable portable concrete mixers may be used.
Treatment and stabilisation of layer work materials in restricted areas shall not be measured separately for payment unless specified otherwise in

A5.4.3.3 Construction limitations
The Contractor shall programme all construction work to take into account all the construction limitations which are applicable to soil treatment
and stabilisation work.
a) Size of area
The cementitious and/or bituminous agent shall only be applied to a surface area the size of which will permit all processing, watering, compacting
and finishing to be completed within the time periods specified in Table A5.4.3-1.
b) Processing time
The construction methods and programme of the Contractor shall take into account and ensure compliance with the processing times specified
in Table A5.4.3-1.
Table A5.4.3-1: Construction time limitations for treatment and stabilisation(1)
Maximum continuous period allowed from the time the application of the chemical agent onto the top
Chemical agent
of the layer commences up until the completion of the stabilisation process
Material modification
Lime 10 hours. The treated layer shall subsequently remain undisturbed for 24 hours.
Material cementation
Cement blends 6 hours until the completion of the compacted layer
Lime 10 hours until the completion of the compacted layer
Material improvement
Bitumen emulsion 12 hours until the completion of the compacted layer
Bitumen emulsion with cement 8 hours until the completion of the compacted layer
Foamed bitumen with or 10 hours until the completion of the layer
without cement
PMPL stabilised crushed stone material
Cement blends 1 hour until the commencement of compaction plus 4 hours until the completion of the compacted
layer.
Wet lean-mix concrete 150 minutes until the completion of the compacted/vibrated layer (reference temperature = 20°C
This time shall be reduced by 30 minutes for every 5°C that the mix temperature exceeds 20°C
Note (1): The construction time limitations shall not exceed the field working time established during the stabilisation design in Clause A4.4.7.1 of
Chapter 4.
c) Trial section approval and testing time

The construction programme and methods of the Contractor shall take into account and ensure compliance with the limitations applicable to the
construction, testing and acceptance of the trial section/s as specified.
d) Weather restrictions
No stabilisation shall be done during windy conditions, wind speed more than 15 km/h (4 m/s), wet weather and cold weather when the air
temperature is below 3°C or with falling air temperatures, 7°C and falling.
No stabilisation work shall be commenced if the surface temperature of a compacted stabilised layer may fall below 1°C during the first three (3)
days after stabilisation. The Contractor shall take the necessary precautions and the construction programme for the stabilisation work shall take
the actual and predicted weather conditions into account.
All stabilised layers damaged by rain, frost or by the formation of ice in the layer shall be removed and replaced by the Contractor at no cost to
the Employer.
e) Traffic limitations
No vehicles or construction equipment except that used for mixing the stabilising agent into the layer shall be allowed to travel over the spread
stabilising agent.
No traffic or construction equipment except that required for curing or priming shall be allowed to travel over the compacted stabilised layer during
the specified curing period as per Clause A5.4.7.6, unless specified otherwise in the Contract Documentation.

A5.4.5 MATERIALS
A5.4.5.1 General
For chemically stabilised layers the natural material or the reclaimed road material, even if previously stabilised, shall comply with the requirements
of Table A4.4.5-2 in Chapter 4.

For bitumen stabilised layers the natural material or the reclaimed road material, even if previously stabilised, shall comply with the requirements
in Table A4.4.5-3 in Chapter 4.
All commercial materials proposed for use by the Contractor or as specified in the Contract Documentation to be stabilised, shall comply with the
requirements of Table A4.4.5-2 or Table A4.4.5-3 in Chapter 4 as applicable.
A5.4.5.2 Material for modification or pretreatment

Material with non-compliant properties, such as the grading, plasticity index and/or CBR strength, that are not compliant for direct use in a stabilised
layer, shall first be mechanically modified and/or chemically pretreated as specified in the Contract Documentation or as instructed by the Engineer.
The materials to be modified shall be identified in the Contract Documentation or by the Engineer during construction and shall be modified to
produce compliant material before any chemical stabilisation is carried out.
a) Mechanical pretreatment of material before stabilisation
Material requiring mechanical modification to improve the grading and/or moderate the plasticity index and/or to increase the CBR strength, in
order for the material to be compliant before stabilisation shall first be prepared and/or treated as specified in Section A5.3.
The mechanically modified compliant material shall then be stabilised with the type and amount of stabilising agent specified in the Contract
b) Cementitious pretreatment of material before stabilisation
Material requiring modification to reduce the plasticity index in order for the material to be compliant for subsequent stabilisation, shall first be
pretreated.
The chemically pretreated, modified and now compliant material shall then be stabilised with the type and amount of cementitious stabilising agent
determined as specified in the Contract Documentation or as instructed by the Engineer.
A5.4.5.3 Cementitious stabilising agents

The Contract Documentation shall specify the type of cementitious agent to be used for the specific gravel or crushed stone material being
chemically pretreated or stabilised. These nominal contents shall then be verified or adjusted based on the laboratory test results and/or after the
construction of a trial section.
A5.4.5.4 Bituminous stabilising agents

The Contract Documentation shall specify the type of bituminous agent to be used for the project for the specific gravel or crushed stone material
being stabilised. These nominal contents shall then be verified or adjusted, based on the laboratory test results and/or after the construction of a
trial section.
A5.4.5.5 Water for stabilisation

Water for the construction of stabilised layers shall comply with the requirements of Clause A4.1.5.18 of Chapter 4.

Construction equipment to carry out the stabilisation or modification of layer work material shall comply with the requirements of Clause A1.2.6 of
Chapter 1.
When either a rotary mixer or a recycler is used to mix in the stabilising agent and process the layer, this construction equipment must be capable
of adding variable but precise amounts of water, and then mixing and placing the material in a single pass in conformance with the design grades
and cross falls.
Where specified in the Contract Documentation, the watering for the curing of compacted stabilised layers shall be done by side-spraying tankers
travelling off the layer.

A5.4.7.1 Construction of a trial section
The Contractor shall demonstrate by constructing one or more of the following trial sections that the equipment and procedure to be used will
result in the construction of layers in accordance with the specifications. The required trial section(s) shall be in accord with the pricing schedule.
• A trial section for the chemical modification or stabilisation of a layer of material processed on the road shall be constructed in accordance
with the relevant requirements of Clauses A5.3.7.12 and A5.4.7 and/or as specified in the Contract Documentation.
• A trial section for the bituminous stabilisation of a layer of material processed on the road shall be constructed in accordance with the
requirements of Clauses A5.3.7 and A5.5.7 and/or as specified in the Contract Documentation.
• A trial section for the cementitious stabilisation of PMPL materials shall be constructed in accordance with the requirements of Clause A5.3.7
and/or as specified in the Contract Documentation.
To allow sufficient time to test and assess all aspects of a trial section(s) and to determine the final content of stabilising agent required, the
Contractor shall programme to start stabilisation work for the works no sooner than 10 working days after completion of the trial section.
Should the Contractor make any alterations to the methods, processes, equipment or materials used, or if the Contractor is unable to consistently
comply with the specifications due to variations in the in-situ material, or for any other reason, further trial sections shall be constructed for
assessment before continuing with the construction of the permanent works as instructed by the Engineer.
In the event of a trial section not being accepted due to non-compliance, the Contractor shall remove the trial section and construct a new trial
section at no cost to the Employer. The trial section shall be paid for separately only when it complies with all the requirements of these
specifications and has been accepted. Once acceptance of the trial section has been obtained, the mixing process and construction equipment
shall remain unaltered unless instructed otherwise by the Engineer.

A5.4.7.2 Mechanical modification of pavement layer material
The specific layer material requiring to be mechanically modified shall be specified in the Contract Documentation or instructed by the Engineer.
When two or perhaps three different pavement layer materials need to be blended in order to provide a compliant composite material the proportion
of each material type shall be specified based on the test results obtained from site blending trials.
a) Mixing materials from various sources in-situ
This Clause for mixing materials from various sources shall only apply when the smallest component of the materials mixture exceeds 20 % of
the total mass of the mixture.
The material from the coarsest material source shall be placed onto the road at the point of use and spread in a layer of uniform thickness after
which it shall be lightly rolled with a steel-wheeled roller. The material from the second and possibly third material source shall then be placed on
top of the spread layer and then evenly spread on top in a layer of uniform thickness. After spreading each subsequent layer, each layer shall be
lightly rolled with a steel-wheeled roller. After evenly spreading the different materials on top of each other, the materials shall be thoroughly mixed
together, broken down if required and then spread evenly again to the required thickness.
The Contractor shall take care to avoid segregation from occurring during the mixing and spreading processes. The grading of the mixed material
shall then be tested at random locations as instructed by the Engineer and further mixing shall be required if grading tests indicate that the material
is not mixed sufficiently.
The finally mixed material shall also be tested for compliance with the specification of all the material properties for use in the specific layer.
b) Modifying material in-situ by the addition of a soil binder
When the smallest component is less or equal to 20 % of the total mass of the mixture then the process shall be regarded as the addition of a soil
binder. The addition of the soil binder may be required to modify the grading or to reduce the plasticity index.
The material to be modified shall be placed onto the road at the point of use and evenly spread in a layer of uniform thickness after which it shall
be lightly rolled with a steel-wheeled roller. The specified soil binder material shall then be placed on top of the evenly spread material and then
evenly spread in a layer of uniform thickness over the first layer of spread material. The soil binder and material shall be thoroughly mixed together,
broken down if required and then spread evenly to the required thickness.
The grading and plasticity index of the mixed material shall then be tested at random locations as instructed by the Engineer and the modified
material shall be tested for compliance with the specification for use in the specific layer.
A5.4.7.3 Chemical pretreatment and stabilisation

The material to be stabilised or pretreated shall be prepared and placed as specified in Section A5.3. The surface of the prepared layer shall then
be lightly watered until it is damp and given at least one pass with a flat wheel or steel tyre roller.
a) Applying the cementitious agent mechanically
After the layer of material has been prepared, the cementitious agent shall be spread uniformly over the full area of the layer by means of an
approved type of mechanical bulk spreader at the prescribed rate of application in a continuous process.
When the mechanical application of the cementitious agent is clearly uneven in places it shall be evenly respread using squeegees where required
so that it is uniformly spread over the entire surface to be stabilised before mixing may commence.
A recycler may be used to mechanically apply the cementitious agent through an on-board automatic dispensing system. Adjacent cuts of the
recycler shall overlap by at least 150 mm. Over application of either moisture or cementitious agent in the overlap shall not exceed 10 % of the
average requirement for the layer.
b) Applying the cementitious agent by hand
When spreading of the cementitious agent is done by hand, pockets or bags of cementitious agent shall be accurately packed out and spaced at
equal intervals across the full area of the section to be stabilised so that the specified rate of application will be achieved. Spreading shall only
commence once it has been confirmed by the Engineer that the correct quantity of cementitious agent has been placed on the layer by physically
counting the number of pockets and checking the spacing of the pockets.
The even spreading of the hand spaced and packed cementitious agent may further be done by hand using squeegees, provided that the wind
speed is less than 15 km/h (4 m/s). Irrespective of the spreading method used the cementitious agent shall be uniformly spread over the entire
surface to be treated.
c) Mixing in the cementitious agent using conventional equipment
Immediately after the cementitious agent has been evenly spread, it shall be mixed with the layer material for the full depth of treatment. The
completed layer underneath shall not be damaged, nor shall the cementitious agent be mixed below the required depth. Mixing shall be continued
until a homogeneous mix of the material and the cementitious agent has been achieved over the full area and depth of the material being pretreated
or stabilised.
Mixing shall be done using a combination of a grader, disc harrow and/or rotary mixer or by using a recycler, working over the full area and depth
of the layer by means of successive passes of the construction equipment as applicable. When a recycler is used in isolation, cross-mixing is
often inadequate and additional mixing plant shall then be utilised in conjunction with the recycler to ensure thorough cross-mixing. Mixing may
also be done in a central batch-mixing plant if the Contractor so chooses.
After completion of the mixing process the mixed material shall be spread and shaped.
If the material is being pretreated, the shaped layer shall be given at least one pass with a flat wheel or steel tyre roller and left undisturbed for
the time period as specified in Table A5.4.3-1. After the specified time period, the chemically modified layer may then be stabilised in accordance
with Section A5.4 if the material is now compliant for stabilisation or processed and compacted as an unstabilised layer in accordance with Section
A5.3.
d) Watering and mixing in of water for stabilisation using conventional equipment
Moisture content tests shall be done the day before the stabilising agent is to be added to the material in order to determine the amount of water
that must be added to bring the moisture content up to the required compaction moisture content. If there is any rain after the moisture content
test samples were collected additional tests shall be done.
Immediately after the cementitious agent for stabilisation has been properly mixed with the material, the required amount of compaction water

shall be added incrementally. Each application of water shall be thoroughly mixed with the material before more water is added so as to avoid a
concentration of water near the surface or the flow of water across the surface of the layer.
The Contractor shall ensure that a satisfactory and even moisture distribution is achieved over the full depth, width and length of the section being
stabilised and shall ensure that no portion of the work gets excessively wet after the cementitious stabilising agent has been added. Any portion
of the work that becomes too wet after the stabilising agent has been added and before the mixture has been compacted, due to poor construction
control or disregard for the specified weather limitations or for any other specified requirement that has not been complied with, shall be rejected.
Such portions shall be allowed to dry out to the required moisture content and shall then be scarified, re-stabilised using additional agent,
compacted and finished off in accordance with the specification, all at no cost to the Employer.
The water supply and watering equipment shall be adequate and sufficient to ensure that all the water required shall be added and mixed with the
material within a short enough period to enable compaction and finishing to be completed within the period specified in Table A5.4.3-1.
The moisture content of the material during compaction shall never exceed 80 % of the saturation moisture content of the natural material without
a stabilising agent.
The moisture content at the specified saturation degree (Sr) shall be determined as follows:
Wv = Sr {Xw/Xd - 1000/Gs}
Wv = moisture content of the specified degree of saturation (%)

Xw = density of water (kg/m3)
Xd = dry field density of the material (kg/m3)
Gs = apparent density of the material (kg/m3)
Sr = specified degree of saturation (%).
e) Applying and mixing in the cementitious agent using a recycler

When the cementitious agent is applied by hand the requirements of Clause A5.4.7.2b) remain applicable.
The requirements of proper moisture control specified in Clause A5.4.7.2d) remain applicable.
The recycler shall be capable of applying the agent and mixing to the required depth in a single pass. The recycler shall be equipped with an on-
board automatic spraying system that can accurately apply a specific metered quantity of water over the full width of the milling drum. Electronic
sensors shall be fitted to maintain the milling/mixing depth within a tolerance of 5,0 mm.
The speed of rotation of the milling drum and the forward speed of the machine shall be adjustable to obtain a material that is evenly mixed with
the cementitious agent. The outer edges of the recycler cut shall be vertical and the floor of the cut shall be clean and to the lines specified in the
Contract Documentation. The width of application shall be the same as the cut-width of the recycler.
The recycler shall be required to simultaneously add the required amount of water and mix the cementitious agent to produce an approved uniform
mix.
f) Compaction of a chemically stabilised layer
Section A5.3 shall apply to the compaction of chemically stabilised layers.
During the compaction process the Contractor shall ensure that no lamination layers or biscuit layers are formed within the compacted layer. Final
rolling shall be done with equipment that will give a smooth surface finish which conforms to the surface tolerances specified. Low spots on the
surface of a chemically stabilised layer may not be filled after compaction.
When a recycler has been used to mix the layer material Contractor shall ensure that the mixed material between the wheel paths of the recycler
is compacted to at least the same density as the material in the wheel paths, before commencing with the cutting of levels.
The minimum compaction requirements shall be as specified for the particular layer. Sufficient compaction equipment shall be employed on each
layer to ensure that, from the time when the stabilising agent is first mixed into the layer, the mixing process, watering, compacting, shaping and
final finishing will be completed within the time periods specified in Table A5.4.3-1.
A5.4.7.4 Bituminous stabilisation

a) In-situ mixing for stabilisation
The material to be stabilised with bitumen shall be prepared and placed as specified in Section A5.3.
(i) Addition of the cementitious agent
If a cementitious agent is specified as part of the bituminous stabilisation process then it shall be evenly spread over the layer
surface (Clause A5.4.7.2) before the bitumen stabilisation process commences.
When using standard construction equipment such as a grader along with a plough / rotovator, the Contractor shall pre-mix the
cementitious agent into the layer as specified (Clause A5.4.7.2) before the compaction moisture and the bituminous stabilising
agent is added and mixed in.
When using a recycler, the cementitious agent shall be mixed in at the same time as the compaction moisture and the bituminous
stabilising agent is being added.
(ii) Heating and diluting the bituminous stabilising agent
The bituminous stabilising agent shall be heated to the required temperature as specified by the supplier.
If dilution of the bitumen emulsion stabilising agent with water is required, only potable water shall be used. The water shall be
added gradually during constant stirring or circulation of the emulsion by means of pumps to prevent the emulsion from separating
or breaking.
(iii) Apply and mix in the bituminous stabilising agent
The bituminous stabilising agent (foamed bitumen or bitumen emulsion) may be applied and mixed into the material using an

approved in-situ recycling machine as specified in Section A5.5.
When a bituminous emulsion stabilising agent is being used it can be applied using a calibrated spray tanker with a spray bar,
followed immediately behind ahead of it being mixed into the material using a grader and a rotovator.
The quantity of material being stabilised with a bituminous stabilising agent must be restricted to the amount that can be properly
mixed with the available equipment before the bitumen emulsion breaks.
b) Remote mixing for stabilisation
Where in-situ mixing and stabilisation is not possible due to a confined working area or inadequate turning space for the construction equipment,
then remote off-site mixing may take place.
(i) Remote site and material preparation
An appropriate site shall be prepared in accord with Section A4.1 of Chapter 4 in the same way a stockpile site is specified to be
prepared.
Place and spread the material on the prepared remote site to a thickness of approximately 300 mm. Place and spread the
cementitious agent as specified in Clause A5.4.7.2 and proceed to mix using appropriate construction equipment such as a grader,
or an articulated loader, or a rotovator.
(ii) Adding the bituminous stabilising agent
Apply the bituminous stabilising agent, heated and/or diluted as specified, using a hand sprayer and then mix the material further.
Once the material has been thoroughly mixed it shall be loaded, hauled, placed and then processed at its point of use, as specified
in Sections A5.3 and A5.4.
A5.4.7.5 PMPL stabilised material

Mixing of the material, water and the stabilisation agent shall be done off site at a central mixing plant. The stabilising agent content and the type
of stabilising agent to be added shall be as specified in the Contract Documentation. The central mixing plant can be used to produce:
• Mixed material for a chemically stabilised gravel layer; or
• Mixed material for a chemically stabilised crushed stone layer; or
• Bitumen stabilised material (BSM); or
• Mixed material for a wet lean-mix concrete,
as specified in the Contract Documentation.
The aggregate or gravel / crushed stone material and the specified type and amount of stabilising agent shall be thoroughly mixed at the mixing
plant either by batch-type mixing with revolving blade or rotating-drum mixers or by the continuous-mixing process with suitable pugmill-type
mixers as appropriate for the type of material being processed. The aggregate, gravel or crushed stone and the stabilising agent shall be measured
by mass.
Where more than one stabilising agent has to be added to the material, the mixing plant shall contain separate hoppers for the different agents
and the introduction of each of these agents into the mix shall be controlled by accurate weighing so as to ensure that the correct quantity of each
agent is added consistently every time.
In all central mixing plants the water may be measured either by mass or by volume and provision shall be made for easily and accurately checking
the quantity of water added per batch or checking the rate of flow of water added when use is made of a continuous mixing plant.
A5.4.7.6 Finishing at joints

This Clause A5.4.7.6 relates specifically to the construction of joints when the material is stabilised and is in addition to the specification in Clause
A5.3.3.7.
Where existing works and new works are joined the material shall be mixed with the stabilising agent and compacted without causing any
permeable or loose patches along the longitudinal or transverse construction joints.
Any completed portion of a stabilised layer adjacent to new work, which is used as a turn-around area by equipment in constructing the adjoining
section, shall be provided with a protective cover of soil or gravel of at least 100 mm thick over a sufficient length to prevent damage to the
completed work.
When the adjoining section is being finished, such cover shall be removed to permit the construction of a smooth vertical joint at the junction of
the completed and adjoining section. Material in the vicinity of the joint which cannot be processed satisfactorily with normal construction
equipment shall be mixed and compacted by hand or with suitable hand-operated machines.
The junctions of sections shall be finished so as to obtain an even and well-compacted joint and so as not to cause damage to the adjacent parts
of any other sections.
A5.4.7.7 Protection and curing of chemically stabilised layers

All stabilised layers shall be protected against rapid drying-out for at least seven days following completion of the layer.
This can be achieved by the frequent application of water for 7 days or by water curing followed by covering with the next layer or by water curing
followed by the application of an approved curing membrane. The use of single-axle trucks with a maximum axle load of 6t shall be used to apply
the chosen curing compound.
The specific method of protection or curing used may be any one of the methods as specified hereunder or as stipulated in the Contract
Documentation.
a) Water curing
The stabilised layer shall be kept continuously wet by watering at frequent intervals for an initial period of 48 hours after the compaction of the
stabilised layer has been completed. The stabilised layer shall thereafter be kept continuously damp for at least a further five days.
Any stabilised layer which is not kept continuously wet or damp for at least seven (7) days, and is by default therefore subjected to consecutive

wet-dry cycles, may be rejected if the layer exhibits shrinkage cracking or any carbonation.
b) Damp protective layer curing
The stabilised layer shall first be cured for 48 hours as specified in Clause A5.4.7.7a).
The stabilised layer shall then be covered with the material required for the next layer. The covering material shall be placed using only single-
axle trucks with a maximum axle load of 6t and then immediately spreading the material. The layer material shall not be compacted. Water curing
of the still exposed portions of the stabilised layer shall continue while the curing layer is dumped and spread.
The material forming the spread layer shall be watered at such intervals as may be required to keep the stabilised layer continuously damp until
it has been cured for at least 7 days. In dry weather the spread layer shall be well watered at least once every 24 hours and even more often in
hot or windy weather conditions.
c) Membrane curing
The chemically stabilised layer shall be covered with a curing membrane consisting of spray-grade bitumen emulsion or cutback bitumen applied
at the rate specified in the Contract Documentation immediately after stabilisation.
d) Prime coat curing
Where a prime coat is specified on top of any stabilised layer, the prime coat may be utilized as a curing membrane and it shall be applied at the
rate specified in the Contract Documentation. Use of the prime coat as a curing membrane may only be applied provided the surface moisture is
only slightly damp and not wet.
If the prime coat is utilised as a curing membrane for a stabilised base layer, payment shall only be made once for the prime coat and no additional
payment will be made for providing a curing membrane.
e) Curing of PMPL layers
PMPL chemically stabilised gravel and PMPL chemically stabilised crushed stone layers shall be cured using one of the methods as specified in
this Clause A5.4.7.6a) to d).
PMPL wet lean-mix concrete layers shall be cured using a concrete curing membrane which shall be sprayed onto the lean-mix concrete layer at
the rate of application specified by the supplier as soon as the initial concrete set has occurred.
A5.4.8 WORKMANSHIP
Any stabilised layers with lamination layers such as biscuit layers, as identified visually and/or by the hollow sound caused when a heavy chain is
dragged over the stabilised layer, shall be rejected.
The material in the rejected sections of the completed layer shall be ripped and removed and replaced with new material. The new material shall
then be stabilised and compacted according to the specifications prior to the construction of any subsequent layers.
Alternatively, the material in the rejected sections can be recycled in-situ with an additional quantity of stabilising agent as determined by testing
and instructed by the Engineer. In-situ recycling will only be permitted provided that the properties of the recycled material are compliant with the
specified requirements for that layer of material.
All remedial work shall be carried out at no cost to the Employer.
A5.4.8.2 Material properties

The test results and measurements of the material quality, compaction density, stabiliser content and the engineering properties of the stabilised
layers shall be assessed in accordance with the provisions of Chapter 20.
A5.4.8.3 Quality/process control

It shall be the responsibility of the Contractor to ensure that the Engineer has been informed in writing of the daily testing requirements. The
material testing can then be properly co-ordinated and completed timeously.
Sample preparation and testing for checking and approving the properties of chemically stabilised material shall be done as per the approved
SANS test methods.
Sample preparation and testing for checking and approving the properties of bituminous stabilised material shall be done as specified in Section
A5.5.
The stabilised material sampled from the layer for the compaction of MDD briquettes shall be prepared according to SANS 3001-GR50 and
compacted according to SANS 3001-GR31.
A5.4.8.4 Tolerances
a) Rates of application
(i) Chemical stabilisation
The average rate of application of a cementitious stabilising agent when applied by mechanical bulk spreading equipment and
measured by the canvas patch method shall be within 5 % of the specified rate of application over any section not exceeding 1,0
km in length. No single measurement shall deviate by more than 20 % from the specified rate.
When hand placed and spread, or spotted, stabilising agents shall be spread exactly to the specified rate of application.
The rate of application of the cementitious stabilising agents added to the material in a central mixing plant shall be controlled by
means of weighing the stabilising agent before it is introduced into the mixing plant.

(ii) Bituminous stabilisation
The rate of application of the bituminous stabilising agent shall be within 5 % of the specified rate in the Contract Documentation.
b) Uniformity of cementitious stabilisation
The quantity of cementitious binder in the mixed material as determined during sampling and testing as specified in Chapter 20, shall be within
the limits specified in the statistical judgement plan described in Chapter 20 using the following formula;
(Sn/ Xn) where;
Sn = the standard deviation of stabiliser
Xn = the average stabiliser content
Where required by the Engineer, the Contractor shall determine the mix uniformity of chemically stabilised layers by means of indirect tensile
strength tests, using SANS 3001-GR54. Samples for the determination of the uniformity of the mix shall be taken immediately after the material
has been mixed with the water and stabiliser and spread, but before the layer is compacted. The Contractor shall therefore make the necessary
arrangements timeously and allow for the time to collect the samples.
As described in Chapter 20, test results shall be adjusted to make allowance for the presence in the material being stabilised of minerals, which
affect the test results. The above requirements for uniformity of mix shall be applied only on condition that the variation in these adjustments falls
within the limits specified in Chapter 20. The coefficient of variation may not exceed 0,3 or 30 % for material mixed in-situ, and 0,2 or 20 % for
material mixed in a central mixing plant.

B5.4 STABILISATION
CONTENTS
B5.4.1 SCOPE
B5.4.2 DEFINITIONS
B5.4.3 GENERAL
B5.4.5 MATERIALS
B5.4.8 WORKMANSHIP
B5.4.1 SCOPE
This Section covers the work requirements for the modification or treatment of the material properties of natural roadbed, fill or pavement layer
materials, by treatment with a soil treatment agent. This treatment normally takes place prior to stabilisation of the respective materials or is used
on its own where stabilisation is not required.
This Section also covers the work requirements for the stabilisation of roadbed, fill, pavement layer materials or plant-mixed paver-laid (PMPL)
layers by the addition of a cementitious stabilising agent and/or a bituminous stabilising agent, followed by a curing treatment.
A proportion of activities as defined in Part A under the various sections are therefore suitable for labour enhancement methods.
B5.4.2 DEFINITIONS
B5.4.3 GENERAL

B5.4.5 MATERIALS


The spreading of the stabilising agents and the cementitious stabilisation of pavement layers are suitable components for labour enhancement.
B5.4.8 WORKMANSHIP

C5.4 STABILISATION
(i) Preamble
otherwise stated.
(ii) Items not measured in this Section
deemed appropriate:
1. All surveying, setting out and level control required for the stabilisation of the pavement layers.
buildings, road signs, guard rails, street lights, fencing, service pipes or cables and any other items adjacent to, over or under the road to
prevent damage by any stabilising agent.
3. Repair of all damage to surfacing and any new or existing structures, buildings and road furniture caused by the stabilising agents.
4. All setting out work required for the accurate application of the stabilising agent specified in the Contract Documentation.
For activities in Table C5.4-1 items specified in other Chapters or Sections of the specification, where they relate to work under this Section, will
be listed in the Pricing Schedule.
Clearing and grubbing - remote mixing A5.4.7.4b)
applicable items
Construction of stockpile site - remote mixing A5.4.7.4b)
applicable items
Procurement of stabilising agents A5.4.5
applicable items
Procurement of commercial materials A5.4.5.1
applicable items
Reclaimed materials A5.4.5.1 Section C5.5 – All applicable items
Processing and compaction of layer material A5.4.7 Section C5.3 – All applicable items
Section C6.1 of Chapter 6 and
Curing – membrane or prime A5.4.7.6c) / A5.4.7.6d)
Chapter 10 – All applicable items

C5.4.1 Pretreatment of gravel layers
C5.4.1.1 Pre-treatment of (insert layer thickness) gravel layer cubic metres (m3)
C5.4.1.2 Pre-treatment of (insert layer thickness) gravel layer using labour enhanced methods of cubic metres (m3)
construction
The unit of measurement shall be the cubic metre of pre-treated material, the quantity of which shall be determined in accordance with the
authorised compacted dimensions of the layer being treated.
No distinction be made in respect of the type of treatment agent used, the time taken for completion, or the specific layer being treated. The rate
tendered shall furthermore apply to any combination of agents. Delivering the agent to the point of use and the distinction in respect of the manner
in which the stabilising agent is spread, whether it be by hand using bags or by mechanical bulk spreader shall be paid under item C5.4.5.
The tendered rates shall include full compensation for watering and compacting the surface of the placed material prior to spreading the
pretreatment agent for mixing the specified amount of pre-treatment agent, for the addition of any water required, and all materials, supervision,
labour, equipment, tools and incidentals necessary for completing the specified work including for leaving the layer dormant for a period of 24
hours after being treated.
Distinction shall also be made in respect of the method of mixing and construction of the layer, either using mechanical methods of construction
or using labour enhancement methods. The layer thickness can be varied by up to 20 mm and the rate for this pre-treatment work shall remain
applicable.

C5.4.2 Chemical stabilisation
C5.4.2.1 Chemical stabilisation (layer thickness indicated) of pavement layers (layer to be stabilised cubic metres (m3)
indicated)
C5.4.2.2 Chemical stabilisation (layer thickness indicated) of pavement layers (layer to be stabilised cubic metres (m3)
indicated) using labour enhanced methods of construction
The unit of measurement shall be the cubic metre of stabilised material, the quantity of which shall be determined in accordance with the authorised
dimensions of the compacted chemically stabilised layers
No distinction shall be made in respect of the type of treatment agent used, the time taken for completion, or the specific layer being treated. The
rate tendered shall furthermore apply to any combination of agents. Delivering the agent to the point of use and the distinction in respect of the
manner in which the stabilising agent is spread, whether it be by hand using bags or by mechanical bulk spreader shall be paid under Item C5.4.5.
The tendered rates shall include full compensation for watering and compacting the surface of the placed material prior to spreading the stabilising
agent, for the mixing of the specified amount of stabilising agent and all materials, supervision, labour, equipment, tools and incidentals necessary
for completing the specified work. No distinction shall be made in respect of the type of cementitious stabilising agent used or the time for
completion or the specific layer being stabilised. Distinction shall be made in respect of the method of mixing and construction of the layer, either
using mechanical methods of construction or using labour enhancement methods. The layer thickness can be varied by up to 20 mm and the rate
for this chemical stabilisation work shall remain applicable.
C5.4.3 Stabilised crushed stone PMPL layer (pavement layer, type of material and source cubic metre (m3)
indicated)
The unit of measurement shall be the cubic metre of stabilised material for the PMPL layer, the quantity of which shall be calculated in accordance
with the authorised dimensions of the final layer.
The tendered rate shall include full compensation for mixing the specified amount of stabilising agent at the central mixing plant and all materials,
supervision, labour, equipment, tools and incidentals necessary for completing the specified work. No distinction will be made in respect of the
type of cementitious stabilisation agent used, the time for completion or the specific layer being treated.
C5.4.4 Wet lean-mix concrete pavement PMPL layer (indicate specific pavement layer): cubic metres (m3)
The unit of measurement shall be the cubic metre of wet lean-mix concrete for the PMPL layer, the quantity of which shall be calculated in
accordance with the authorised dimensions of the final layer.
The tendered rate shall include full compensation for mixing the specified amount of cementitious agent, water and material at a mixing plant
(PMPL) and all materials, supervision, labour, equipment, tools and incidentals necessary for completing the specified work. No distinction will be
made in respect of the type of cementitious stabilisation agent used, the time for completion or the specific layer being treated.
C5.4.5 Cementitious stabilisation agents for pavement layers
C5.4.5.1 Addition of cementitious stabilisation agents (specify agent separately) for pavement layers
(a) Cement (for pavement layer) ton (t)
(b) And so forth for other agents (for pavement layers) ton (t)
C5.4.5.2 Addition of cementitious stabilisation agents (specify agent separately) for pavement layers
and spreading the agent using bags and labour enhancement methods.
(a) Cement (for pavement layer) ton (t)
(b) And so forth for other agents (for pavement layers) ton (t)
The unit of measurement shall be the ton of cementitious stabilising agent spread and mixed into the prepared layer material in-situ.
The tendered rates shall include full compensation for the supply and delivery of the agent to the point of use. The tendered rates shall also include
for spreading the specified amount of cementitious stabilising agent, and all materials, supervision, labour, equipment, tools and incidentals
necessary for completing the specified work. The layer thickness can be varied by up to 20 mm and the rate for this work shall remain applicable.
A distinction shall be made between spreading the cementitious soil stabilisation agents by mechanical bulk spreaders or using labour
enhancement methods.

C5.4.6 Addition of cementitious stabilisation agents (specify agent separately) for a PMPL layer
C5.4.6.1 Cement ton (t)
C5.4.6.2 And so forth for other agents ton (t)
The unit of measurement shall be the ton of cementitious stabilising agent mixed into the material at a central mixing plant at the specified
application rate.
The tendered rates shall include full compensation for delivery of the agent from storage to the mixing plant and introducing the specified amount
of cementitious agent and water into the mixing plant for the PMPL layer and all materials, supervision, labour, equipment, tools and incidentals
necessary for completing the specified work. No distinction shall be made in respect of the type of cementitious stabilisation agent used, the time
for completion or the specific layer being produced whether that is a wet lean-mix concrete or a chemically stabilised crushed stone material.
C5.4.7 Bituminous stabilisation of pavement layers cubic metres (m3)
C5.4.7.1 Bituminous stabilisation (layer thickness indicated) of pavement layers (layer to be indicated) litres (ℓ)
C5.4.7.2 Bituminous stabilisation (layer thickness indicated) of pavement layers (layer to be indicated) litres (ℓ)
using labour enhanced methods of construction
The unit of measurement shall be the cubic metre of stabilised material, the quantity of which shall be determined in accordance with the authorised
dimensions of the bituminous stabilised compacted layer.
The tendered rates for bituminous stabilisation shall include full compensation for watering and compacting the surface of the placed material prior
to spreading the stabilising agent, for mixing the specified amount of stabilisation agent and material and shall include full compensation for all
incidentals. No distinction shall be made with regard to the type of bituminous stabiliser used, the time for completion, and the particular layer to
be stabilised with bitumen. The tendered rate shall apply to any combination thereof.
The layer thickness can be varied by up to 20 mm, and the rate for this cementitious stabilisation work shall remain applicable.
A distinction shall be made between spreading the cementitious soil stabilisation agents by mechanical bulk spreaders or using labour
enhancement methods.
C5.4.8 Bituminous stabilisation agent (specify agents separately)
C5.4.8.1 60 % anionic emulsion litres (ℓ)
C5.4.8.2 60 % cationic emulsion litres (ℓ)
C5.4.8.3 Foamed bitumen litres (ℓ)
C5.4.8.4 Any other litres (ℓ)
The unit of measurement shall be the litre of bituminous stabilising agent mixed into the road layer at the specified application rate. For bitumen
emulsion this shall be the litre of 60 % emulsion mixed into the material. For foamed bitumen this shall be the litre of bitumen that is foamed.
For bitumen emulsion stabilisation the tendered rates shall include full compensation for diluting and introducing the specified amount of
stabilisation agent at the point of use, and shall include full compensation for all incidentals. No distinction shall be made in regard to the type of
bituminous stabiliser used, the method of application, the time for completion, and the particular layer to be stabilised with bitumen and the
tendered rates shall apply to any combination thereof. The layer thickness can be varied by up to 20 mm, and the rate for this bituminous
stabilisation work shall remain applicable.
For foamed bitumen, the rate shall also include for foaming the bitumen on the recycler, including the water and any other additive that may be
required to achieve the minimum foaming characteristics and for injecting the foamed bitumen into the material being processed
The tendered rates shall also include full compensation for heating and the transfer into tankers of the bitumen. It shall also include for coupling
to the recycling train, for all transport on site, for any re-heating required, for all wastage and for strict adherence to all safety measures required
when handling warm or hot bitumen.
C5.4.9 Filler for bituminous stabilisation
C5.4.9.1 Filler for bituminous stabilisation (specify agents separately) ton (t)
C5.4.9.2 Filler for bituminous stabilisation spreading the agent or filler using labour enhanced methods ton (t)
of construction (specify agents separately)
The unit of measurement shall be the ton of cementitious agent mixed into the road layer at the specified application rate.
The tendered rates shall include full compensation for the supply and the blending of the specified amount of filler with the bituminous stabilisation
process and all materials, supervision, labour, equipment, tools and incidentals necessary for completing the specified work. No distinction will be
made in respect of the type of filler used, the time for completion or the specific layer being treated.
A distinction shall be made between spreading the filler by mechanical bulk spreaders and using labour enhancement methods.

C5.4.10 Provision and application of water for curing kilolitre (kℓ)
The unit of measurement shall be the kilolitre of water provided and applied for curing a chemically stabilised layer.
The tendered rate shall include full compensation for furnishing, transporting and applying the water.
C5.4.11 Curing by covering with the subsequent layer square metre (m2)
The unit of measurement shall be the square metre of chemically stabilised pavement layer being cured by covering it with the subsequent layer.
The quantity will be determined by the plan area of the authorised dimensions of the layer being cured
The tendered rate shall include full compensation for incidentals in respect of applying the subsequent layer for curing as specified, including the
cost of regularly supplying and applying water.
C5.4.12 Curing with a membrane (type of material to be specified)
C5.4.12.1 Cut back bitumen litre (ℓ)
C5.4.12.2 Inverted bitumen emulsion litre (ℓ)
C5.4.12.3 Spray grade emulsion litre (ℓ)
C5.4.12.4 Curing compound for PMPL layers litre (ℓ)
The unit of measurement shall be the litre of curing material measured at spraying temperature and sprayed as specified.
The tendered rates shall include full compensation for supplying the material, preparation of the surface before applying the curing membrane,
applying the membrane material and maintaining the surface as specified.
C5.4.13 Trial section for a PMPL layer (specify width) square metre (m2)
The unit of measurement for the trial section of the plant-mixed paver-laid pavement layer shall be the square metre of trial section of the specified
width as specified in the Contract Documentation measured along the centre line of the road. A total length of at least 250m of trial section and
no more than 350 m will be measured for payment as a trial section.
The tendered rate shall include full compensation for supplying, introducing and mixing the cementitious stabilising agent at the specified rate at
the mixing plant for the construction of the trial section.
C5.4.14 Trial section for a chemically stabilised layer cubic metre (m3)
The unit of measurement for the trial section of a chemically stabilised pavement layer shall be the cubic metre of trial section as per the authorised
dimensions. A total length of at least 150 m of trial section and no more than 200 m will be measured for payment as a trial section.
The tendered rate shall include full compensation for placing spreading and mixing the stabilising agent at the specified application rate during
the construction of the trial section.
C5.4.15 Trial section for a bituminously stabilised layer (specify width) square metre (m2)
The unit of measurement for the trial section of a bituminously stabilised pavement layer shall be the square metre of trial section of the specified
width as specified in the Contract Documentation measured along the centre line of the road. A total length of at least 250 m of trial section and
no more than 350 m will be measured for payment as a trial section.
The tendered rate shall include full compensation for placing spreading and mixing the bituminous stabilising agent and filler at the specified
application rate during the construction of the trial section.
C5.4.16 Mechanical modification cubic metre (m3)
The unit of measurement shall be the cubic metre of material in the compacted layer which has been mechanically modified as per Clause
A5.4.7.2a) calculated using the layer work dimensions given in the Contract Documentation.
The tendered rate shall include full compensation for mixing all the different materials together to form one homogeneous layer as per Clause
A5.4.7.2.
Payment for the construction operations required to process and compact the modified layer shall be made under item C5.3.2.
C5.4.17 Addition of a soil binder cubic metre (m3)
The unit of measurement shall be the cubic metre of soil binder added to and mixed into the pavement layer as per Clause A5.4.7.2b). The volume

of soil binder shall be calculated using the completed layer work dimensions given in the Contract Documentation multiplied by the percentage by
volume of soil binder added as specified.
The tendered rate shall include full compensation for mixing the soil binder into the layer to form one homogeneous layer.
Payment for the construction operations required to process and compact the modified layer shall be made under item C5.3.2
.

D5.4 STABILISATION
CONTENTS
D5.4.1 SCOPE
D5.4.2 GENERAL

5.5 RECONSTRUCTION OF PAVEMENT LAYERS
CONTENTS
A5.5.1 SCOPE
A5.5.2 DEFINITIONS
A5.5.3 GENERAL
A5.5.5 MATERIALS
A5.5.8 WORKMANSHIP

A5.5 RECONSTRUCTION OF PAVEMENT LAYERS

A5.5.1 SCOPE
This Section covers the work requirements for the reconstruction of existing road pavement layers. This comprises patching and in-situ
reconstruction.
A5.5.1.1 Patching
Patching covers the work requirements for the patching of existing pavement layers, and in exceptional cases patching fills and the roadbed, with
the purpose of repairing local failures. Patching involves excavating the existing failed sections to the specified depth and area, removing the
excavated material and reconstructing the excavated fills and pavement layers with the specified material.
Patching specified in this Section A5.5 is applicable when the project scope of works is predominantly the reconstruction of Pavement Layers.
Patching specified in Section A8.8 is applicable when the project scope of works is predominantly the construction of Asphalt Layers.
This scope also covers the work requirements for the repair of edge breaks.
Resurfacing the repaired failed area does not form part of this scope and is provided for in Chapters 8 and 9.
A5.5.1.2 In-situ reconstruction

In-situ reconstruction covers the work requirements for the process using either conventional construction equipment exclusively or a custom-
designed recycling machine (recycler) along with some conventional construction equipment, to reconstruct pavement layers.
A5.5.2 DEFINITIONS
The relevant definitions in the standard specification are applicable. Additional definitions for this Section are included here.
Conventional equipment - this is equipment that is normally used for the construction of the Works. This equipment excludes equipment
specifically designed and used for in-situ reconstruction works and/or for the recycling of materials.
Cross-mixing - this is the mixing of layer materials horizontally across a layer width when the material properties of the layer are not the same
throughout the width and the depth of the layer. Cross-mixing cannot be carried out using a recycler.
Edge break - an edge break is a defect in which the outer edge of the wearing course and part of the underlying pavement layer (asphalt or
crushed stone or gravel) is broken and/or worn away resulting in an irregular road edge line with an average defect width of 250 mm or less. Edge
breaks wider than 250 mm are defined as patching.
In-situ - this means in the actual original or final location without moving the material elsewhere.
Patching - means the repair of failures in fill and/or pavement layers when the failed width is less than 1,0 m or the failed length is less than 25
m or the failed area is less than 100 m2. Patching does not include the pretreatment of a surfacing, or the repair/patching of surfacing defects, or
the rehabilitation of a concrete pavement which is covered in Chapters 8 (pretreatment), 8 (surface defects) or 7 (repair of concrete).
Reconstruction - this is the reconstruction of existing pavement layer material (in-situ or reclaimed material) with or without stabilisation.
Reconstruction in several construction phases can be accomplished using conventional construction equipment to reclaim and reconstruct layer
work material or in a single construction phase using a recycler along with some conventional construction equipment to achieve the reclaiming
and reconstruction of layer work material.

Rehabilitation - this is the restoration of an existing deteriorated or failed road pavement either to the original constructed condition or to a better
condition. The restoration of the road pavement can take place by patching, by layer reconstruction, by adding layers or a combination of the
aforementioned as specified in the Contract Documentation.
Recording pass - this is the roller-pass when the roller’s compactometer readings are recorded, cross-referenced to a location and compared
with the specified layer density requirements. A recording pass is only made on the second roller-pass over the same area. A recording pass
comprises two passes with the roller.
Slushing - the process of wetting the surface of a compacted layer accompanied by rolling with a smooth-drum roller and/or a pneumatic tyre
roller to generate saturated fine material or slush, on the upper surface of the compacted layer.
Uniform pavement section - a uniform pavement section has pavement layers with similar layer materials, similar layer properties, similar layer
thicknesses and similar deflection responses (when available) throughout the section. Uniform pavement sections shall be clearly identified in the
A5.5.3 GENERAL
A5.5.3.1 Traffic accommodation
The traffic accommodation arrangements required during the reconstruction of existing roadworks in urban and rural areas are specified in Chapter
1 of the specifications.
The works-specific details shall be specified in the Contract Documentation.
A5.5.3.2 Material selection

The reclaimed material specifications in this Section are supplementary to the material specifications of Chapter 4. Reclaimed material from
existing pavements shall be utilised as specified in the Contract Documentation.
All reclaimed material from existing pavements, or reconstructed in-situ, shall be broken down and oversize material removed, to comply with the
maximum size and grading requirements for the particular use of the reclaimed material as specified in the Contract Documentation.
The classes of excavation for reclaimed material shall be as specified in Section A4.3 of Chapter 4.
A5.5.3.3 Construction requirements

The processing, compaction, stabilisation, finishing and protection requirements of the in-situ material or reclaimed material as specified in
Sections A5.1 to A5.5 shall apply to the construction of reclaimed material and to the reconstruction of in-situ pavement layers.
In addition, the processing and compaction of materials for patching shall also be carried out as specified in the relevant Sections of Chapter 5.
A5.5.3.4 Existing bituminous seal and/or asphalt layers

Thin bituminous seal surfacing layers are usually processed together with the underlying pavement layer or layers which are being reclaimed or
reconstructed in-situ, unless the complete removal thereof is specified in the Contract Documentation.
Asphalt surfacing and/or asphalt base layers may be reclaimed by milling off to stockpile as specified in Clauses A4.3.7.4 to A4.3.7.6 or they may
be reconstructed in-situ, together with the underlying pavement layer(s).
Bituminous seal surfacing or asphalt base and/or surfacing layers which are processed together with the underlying gravel or crushed stone
pavement layer/s shall be properly broken down by the milling and reconstruction process and mixed thoroughly with the underlying material and
to the depth as specified in the Contract Documentation. Any remaining fragments of the bituminous seal surfacing or asphalt material which
exceed the specified maximum particle size of the pavement layer being reprocessed shall be broken down or removed as oversize material.
A5.5.3.5 Reconstructing existing pavement layer materials

Where the existing pavement material is to be reconstructed in-situ as base, the exposed surface shall be cleaned by removing all remaining
fragments of asphalt material. No more than 15 % of the exposed surface area shall still be covered but with a reduced thickness of no more than
10 mm of asphalt material.
The existing pavement material shall be broken down to the full depth and then reconstructed in-situ, as specified in the Contract Documentation
A5.5.3.6 In-situ reconstruction near existing road infrastructure

Care shall be exercised to avoid damage to any concrete elements, expansion joints, joint nosings, manholes, kerbing, catch pits and any other
roadside furniture during reconstruction of the layers. Damage caused to any element forming part of the permanent works shall be repaired at
no cost to the Employer.
A5.5.3.7 Exposed pavement layer

The exposed surface of the in-situ layer left after a pavement layer has been excavated, shall be inspected once the exposed surface has been
cleaned of all loose material by sweeping, or blowing with compressed air or by vacuuming.
Irrespective of whether the exposed layer is an unstabilised layer or a stabilised layer the cleaned floor of the excavation shall be inspected for
any failed areas and for cracks of any form by the Contractor along with the Engineer.
A5.5.3.8 Widening an existing pavement

Where existing roads need to be widened, the existing pavement layers shall be cut back to a firm, well-compacted or cemented material ahead
of the commencement of any widening activities. The cut back material may be used together with imported material in the widening process as
Where pavement layers are widened, then the different existing pavement layers shall be excavated in steps or benches as specified in Clause
A5.3.3.7.
If there is a restricted working space caused by the widening of an existing pavement over a narrow width, the Contractor shall ensure that all
material complies with the specified maximum aggregate sizes before the material is brought into the restricted working space. No further breaking

down on the road shall be permitted within the restricted working space unless the Contractor can demonstrate that the oversize material can be
broken down or removed successfully without compromising the safety of workers or members of the public using the adjacent road.
A5.5.3.9 Programme of reconstruction work

All reconstruction work shall only take place in accordance with the accepted reconstruction programme which the Contractor shall compile and
submit to the Engineer prior to commencing the reconstruction of each uniform road pavement section. The programme shall be regularly updated
and submitted to the Engineer at the end of each week.
Prior to the start of each single-operation of work, the Contractor shall prepare a M&U plan detailing proposals for the work. This plan shall at least
include the following:
• The overall layout of the length and width of road intended to be reconstructed during the single-operation. The width shall be divided into
the number of parallel cuts (for a recycler) or width of construction (for conventional equipment) required to achieve the specified overall
width of reconstruction.
• The location of overlaps and the overlap width (minimum overlap of 150 mm) at each longitudinal joint between adjacent cuts/widths.
• The location of the inner and outer wheel paths of each construction lane affected by the reconstruction.
• The sequence and length of each cut/width to be reconstructed before starting on the adjacent or following cut/width.
• An estimate of the time required for the reconstruction along each cut/width and for finishing off the work.
A5.5.3.10 Contractor M&U plans for the reconstruction of layerworks

The Contractor shall prepare and submit a management and utilisation (M&U) plan for the reconstruction of existing layerworks to ensure that it
is worked in a sustainable and sensitive manner, to ensure that the environmental impact is minimised, that material use and haulage are optimised
and that the work is carried out in a cost-effective manner. Every reconstructed layer in each uniform section shall require a M&U plan to be
submitted. The Engineer can approve that a representative M&U plan be submitted for the reconstruction of layers where the material type, road
particulars such as road width, traffic accommodation and reconstruction methods only differ slightly.
The M&U plan shall at least take cognizance of the following and provide detail of the following as appropriate:
• The intended traffic accommodation methodology and phasing.
• The pavement layer patching programme.
• A method statement and programme for the reconstruction of each of the pavement layers including the reclaiming of existing road materials,
the breaking down and processing in-situ of an existing pavement layer and the completion of each layer.
• Details of the programme for the movement of materials to ensure that the material is not handled unnecessarily.
• The survey methods to be used to set out and control the levels and width of the pavement layers for each processed layer.
• A method statement for the construction of a trial section using a recycler and/or using conventional equipment as applicable.
• A method statement of how oversize material will be dealt with.
• Measures to comply with the general and specific conditions of the road environmental management plan.
• Measures to comply with safety regulations and obligations in terms of the relevant Health and Safety Acts and Regulations.
• The full quality and process control testing detail for the applicable materials tests along with the frequency and quantity of such testing for
each constructed section of each layer to ensure full compliance of the constructed layer in terms of compaction density, material quality and
stabilisation testing (visual and laboratory), and
• Procedure for the regular monitoring, auditing and reporting.
plan will be submitted for review. The reconstruction of a particular layer shall only commence once the Contractor’s M-&U plan for that layer and
uniform section has been reviewed and accepted by the Engineer. The Engineer shall respond within one week after receiving an M&U plan.

The Contractor shall be permitted to submit an alternative individual layer design and/or alternative pavement design.
The predicted pavement life for any alternative design submission shall be the same expected life as that of the original pavement design in the
A5.5.5 MATERIALS
The Contractor shall ensure that reclaimed material complies with the specified requirements of Chapter 4 prior to use in the particular pavement
layer.
Further specifications for patching of existing road pavement layers and for the processing and compaction of existing road pavement layer
materials using a recycler, are contained in this Section A5.5.
A5.5.5.1 Existing crushed stone pavement materials

Where existing crushed stone material is to be reconstructed, the Contract Documentation shall specify whether the material shall be processed
as a gravel layer or as a crushed stone layer.
The compaction requirements specified in Table A5.3.5-2 shall apply to crushed stone layers constructed from reclaimed or in-situ reconstructed
material unless specified otherwise in the Contract Documentation.

A5.5.5.2 Stockpiling reclaimed asphalt and reclaimed pavement material
Stockpile sites for reclaimed asphalt and reclaimed pavement materials shall be constructed as specified in Clauses A4.1.7.3a) of Chapter 4.
When asphalt material is reclaimed and stockpiled for reconstruction, the surface of the stockpile area shall also be constructed as specified in
Clauses A4.3.7.12a) of Chapter 4.
Reclaimed asphalt (RA) from the same uniform source shall be stockpiled as per Clause A4.1.7.3b) of Chapter 4 in the same stockpile and in
immediately adjacent stockpiles, when a new stockpile is commenced. The requirements in this Clause A5.5.5.2 are in addition to those in Clauses
A4.1.7.3b) and A4.3.7.12b) of Chapter 4.
Each stockpile of reclaimed asphalt (RA) shall be constructed in such a manner that will restrict segregation and compaction of the stockpiled
material as follows:
• Each stockpile shall not exceed 1000 t.
• The stockpile shall not exceed a height of 2,5 m to prevent consolidation of the RA.
• The RA stockpile shall be located on the sloping stockpile site so that the water drains away from the loading end.
• The stockpile shall be shaped so that water drains off the top and down the stockpile side slopes.
• Side slopes shall not be steeper than 1 vertical(V) : 2 horizontal(H).
• The loads of RA shall be dumped uniformly over the entire RA stockpile area.
• A light bulldozer or front-end loader shall then doze the material into a ramp-shaped stockpile, in layers.
• Travel on the stockpile by heavy equipment such as the front-end loader or the light bulldozer shall be minimized.
• Trucks shall not travel on the stockpile.
Reclaimed gravel or reclaimed crushed stone material from the same uniform sources shall be stockpiled as per Clause A4.1.7.3b) of Chapter 4
in the same stockpile and in immediately adjacent stockpiles, when a new stockpile is commenced. The requirements in this Clause A5.5.5.2 are
in addition to those in Clauses A4.1.7.3b) and A4.3.7.12b) of Chapter 4.
Each stockpile of reclaimed pavement materials shall be constructed in such a manner that will restrict segregation and compaction of the
stockpiled material as follows:
• Each stockpile of reclaimed material shall not exceed a height of 3,0 m.
• Side slopes shall not be steeper than 1V:2H.
• The loads of reclaimed material shall be dumped uniformly over the entire material stockpile area.
• A light bulldozer or front-end loader shall then doze the material into a stockpile in layers.
• The reclaimed material shall be placed in layers no more than 1,0 m thick. Each layer shall be completed and levelled prior to placing
the next layer.
• The layers shall be constructed horizontally or constructed at a maximum slope of 1V:3H.
• Trucks shall not travel on the stockpile.
After the stockpiled material has been removed the stockpile site(s) shall be reinstated as per Clause A4.1.7.3c).
A5.5.5.3 Imported materials for patching

The imported materials used for patching shall comply with the material specifications of Section A4.1 of Chapter 4 for the specific layer being
reconstructed in the patch.
A5.5.5.4 Compaction density

The density of the reconstructed layer shall be measured in terms of the MDD of the layer.
The minimum compaction density for reconstructed pavement layers shall be as specified in Table A5.5.5-1.
Table A5.5.5-1: Minimum compaction density for reconstructed material
Compaction as % of maximum dry density (MDD)
Reconstructed material type
Cementitious stabilisation Bituminous stabilisation
Natural gravel as per Table A5.3.5-1 100
Graded crushed stone as per Table A5.3.5-2 102
A5.5.5.5 Material shortfall and make-up material

Where there is a shortfall of material for the reconstruction of a layer or layers, this shortfall shall be imported from compliant material prepared in
accord with the specification in Chapter 4 from stockpile or from commercial sources as specified in the Contract Documentation. The shortfall of
material may be due to the poor shape of the road pavement or due to poor levels or to a deficient as-built layer thickness.
The grading and other properties of the in-situ material blended with the imported material shall be determined. Where the grading of this layer to
be reconstructed is not compliant either in-situ, or after being milled, or after being ripped and broken down, then make-up material shall be
imported and blended with the in-situ material so that the combined grading and other material properties of the in-situ reconstructed layer shall
be as specified.
Nowhere shall the thickness of imported material exceed two thirds of the depth of reconstruction.

Construction equipment to carry out the rehabilitation or reconstruction of existing layer work material shall comply with the requirements of Clause
A1.2.6 of Chapter 1, Section A4.3 of Chapter 4 and Clause A5.4.6.
When a recycler is used as part of the layer processing operation, this construction equipment must be capable of mixing and placing the material
in a single pass, to line, level and cross-fall.

A5.5.6.1 Construction equipment for patching
All construction equipment shall be suitable for the specific use and size of working area and be capable of completing all the specified construction
work within the construction tolerances.
The Contractor shall prepare the list of construction equipment required for the type and extent of patching for the specific project. The following
types of construction equipment are typically required for patching:
• Pedestrian and small ride-on roller.
• Vibratory plate compactor.
• Mobile compressor with matched paving breakers.
• Mechanical saw and hand tools.
• Hand-operated compactor.
• Mobile concrete mixer.
• Tractor loader backhoe (TLB) or small front-end loader.
A5.5.6.2 Construction equipment for in-situ reconstruction

All in-situ reconstruction shall be done using conventional construction equipment or using a custom-designed recycling machine hereinafter
referred to as a recycler.
These requirements are specific and are in addition to conventional construction equipment requirements specified elsewhere in Clause A1.2.6
of Chapter 1 and Clause A5.4.6.
a) Recycler
(i) Recycler performance
The recycler shall comply with the following requirements:
• The recycler shall have sufficient power to break down and mix the existing pavement material while pushing or pulling bulk
supply tankers.
• Have a level-control system which is capable of maintaining the cut depth within a tolerance of 10 mm of the specified depth
during continuous operation.
• The cutter shall have a minimum cut width of 2,0 m with the capability to change the speed of rotation and forward movement.
The machine shall be capable of reconstruction to the specified depth in a single pass. Maximum depth capability of the
recycler shall be 0,4 m.
• The maximum speed of advance recommended by the manufacturer of the particular recycler shall be provided by the
Contractor for acceptance. A maximum speed of advance of 10 m/min shall not be exceeded.
(ii) Recycler liquid application
The liquid application system of the recycler shall comply with the following requirements:
• A liquid application system dedicated to adding water to the material in the mixing chamber shall be fitted.
• Where a bituminous stabilising agent is to be applied, a second separate liquid application system shall be fitted to add the
stabilising agent to the material in the mixing chamber. The system shall be appropriate for the addition of either bitumen
emulsion or foamed bitumen as required.
• The application systems shall be controlled by a micro-processor / flow meter combination that can accurately regulate pump
delivery or flow rate in accordance with the speed of advance of the recycler and the volume of material being processed.
• All liquid application systems shall include a dedicated spray bar that spans the full width of the mixing chamber. Each spray
bar shall be equipped with multiple injection nozzles mounted equidistant along the length of the bar at a maximum interval
of 200 mm with the ability to close off selected nozzles, thereby allowing the required width of application to be set.
• Where two liquid application systems are used, the water application spray bar shall be mounted ahead of the other spray bar
(relative to the direction of rotation of the cutter) such that the material encounters the water spray before encountering the
stabilising agent.
The liquid application system shall also have the following specific features installed on the recycler, for foamed bitumen:
• Each injection nozzle on the spray bar fitted with an expansion chamber capable of adequately foaming the bitumen.
• Gauges installed on the bitumen supply line for monitoring the bitumen temperature and pressure.
• A feature to demonstrate that all expansion chambers are free of blockages in both the water and bitumen feed lines.
• A test nozzle to provide a representative sample of foamed bitumen at any stage during normal operations.
• A micro-processor that shall continuously monitor the actual bitumen consumption whilst working and provide a continuous
accumulative total that allows immediate reconciliation with the theoretical consumption required to meet the specified nett
bitumen application rate.
(iii) Mixed material placement by the recycler and subsequent compaction
The recycler shall be capable of breaking down the material to the specified depth in the layer or layers of the existing pavement
and then blending that material together with additional material as and when required, with a stabilising agent, with water and
any other specified agents or additives. The machine shall be capable of breaking down the material and of achieving the required
blend and consistency of mix in a single pass.
The in-situ material mixed by the recycler and then levelled and placed behind the recycler, shall be compacted using suitable
compaction equipment and graders to construct a layer that meets the specified requirements.
Sufficient construction equipment shall be utilised to enable the stabilised material to be processed and finished within the time
limitations specified in Table A5.4.3-1.
b) Milling machine
When the Contractor intends to use construction equipment such as a track-mounted milling machine to pulverise the existing layer material in-

situ, followed by the use of conventional construction equipment to further process the pulverised material, comprehensive details of the alternative
construction equipment shall be submitted for review and acceptance.
When a milling machine is only used to pulverise the existing material, followed by conventional construction equipment to process the pulverised
material, this conventional construction equipment shall be capable of mixing the required material with the stabilising agents and produce a
uniform mix consistency.
The basic requirements for a milling machine are given in Clause A4.3.6.2 of Chapter 4.
c) Spreaders for applying filler

Where filler is spread on the road surface using a mechanical spreader, the low spread rate required when applying ≤1% by mass requires a
special type of spreader.
Special units that utilise a cellular wheel for metering the powder can accurately apply rates as low as 0.7% and are, therefore, ideal for spreading
active filler on a reconstruction project utilising bitumen stabilisation.
d) Heavy duty motor grader

A heavy duty motor grader (minimum 120 kW and minimum 14 ton) is an essential item of plant. The grader is required to pre-shape the material
prior to treatment, for processing the material and to cut final levels once all the material processing is complete.
Grader processing includes mixing the material prior to treatment and mixing in the filler and bitumen emulsion. Depending on the volume of
material being mixed and the quantity to be treated in a single shift, more than one grader may be required.
e) Water tanker
Self-propelled water tankers with a minimum capacity of 15 000 litres are essential.
Water tankers involved with bitumen emulsion stabilised materials shall only ever transport diluted emulsion. Each water tanker must be equipped
with a circulating pump system to circulate the emulsion after standing for two days and before each water tank spray. These water tanks shall
not be equipped with a spraybar but with a concave dish located beneath a vertical outlet pipe. The emulsion must be released by opening an
audco-type valve immediately above the concave dish. The shape of the concave dish will ensure a widespread spray distribution of emulsion.
This is a cold application process of emulsion.
f) Compaction equipment
The primary compaction rollers shall be selected by the Contractor to suit the material type and layer thickness being compacted and to achieve
the specified density requirements. A primary compaction roller may be a single drum vibrating roller. A padfoot drum is normally fitted to the
primary roller when the layer thickness exceeds 150 mm. A pneumatic-tyred roller (PTR) may be used along with a padfoot primary roller as the
primary compaction roller combination when processing fine material. A padfoot roller along with a smooth drum roller may be used as the primary
compaction rollers to compact a coarse material.
Table A5.5.6-1: Primary roller: Recommended static mass
Layer thickness (mm) Static mass (ton)
< 150 12
150 - 200 15
200 - 300 20
300 - 350 25
The secondary compaction rollers shall be selected by the Contractor for finishing the surface of the layer such as a suitable smooth-drum vibratory
roller and/or a PTR or in combination.. A single or tandem smooth drum roller may be used. The rollers shall be used to compact the upper portion
of the layer and to produce a well-knit, smooth surface finish.
A 20 ton PTR as a finishing roller may work well once the grader has completed cutting the layer to level and cross-fall, to achieve a tightly-knit
surface finish.
A trial section shall be constructed to resolve the best roller combinations for the primary rollers, the secondary rollers and the finishing rollers.
g) Static storage tanks and bulk tankers

Bulk tankers with sufficient capacity to match the production rate of the recycler shall be used to supply the recycler “on the move” with water and
liquid stabilising agents.
Static tanks used for the storage and supply of bituminous stabilising agents to the recycler and/or to conventional construction equipment shall
be equipped with a circulating pump system. The stored emulsion shall be properly circulated every 2 days. A thermometer to measure the
temperature of the bitumen in both the top and bottom halves of the supply tank must be installed in the static tank.

A5.5.7.1 Patching
The excavation and backfilling of all patching work, complete as specified for a patch, shall be carried out and completed on the same day when
under traffic. When the portion of road being patched is temporarily closed to all traffic, the patch excluding the wearing course, shall still be
completed on the same day unless specified otherwise.

The applicable specifications in Chapters 4 and 5 shall be applicable to the construction of each layer to be processed as part of a patch repair.
a) Patch demarcation
The Contractor shall be responsible for accommodating the traffic in accordance with the specified requirements during the demarcation work.
Areas to be patched shall be demarcated on site by the Contractor in conjunction with the Engineer. The Contract Documentation shall specify
the various types of patching expected to be done for the various failed areas of the road section. Each demarcated area shall be cross-referenced
to one of the repair types.
The Contractor shall give at least 4 calendar days notice to the Engineer of the intention to commence with repair work of any nature on any
specific section of the road, so that there is sufficient time to demarcate the areas to be patched.
b) Excavating existing pavement material
All excavations for patching shall have a neat rectangular shape. The existing material shall be excavated and removed to the full specified depth.
Asphalt surfacing layers shall be saw-cut along the patch perimeter before any excavation work may commence.
The sides of the excavation for patching shall be cut vertically (by saw-cutting or using pneumatic tools) through each existing layer with a
maximum allowable horizontal deviation from the vertical, of 6V:1H which is equivalent to 25 mm horizontal deviation for each 150 mm excavated
layer depth. The saw-cut location for each successive layer shall be moved horizontally by 150 mm to ultimately create stepped layers around the
perimeter of the patch excavation.
Excavation may also be done using a milling machine when appropriate.
Excavated material from each pavement layer shall be placed in separate stockpiles adjacent to the patch. The stockpiled material shall be re-
used or spoiled as specified.
The floor of the excavation shall be compacted in-situ, if the layer density is not compliant with the specified density for that particular layer.
After completion of the patch excavation to the specified depth, the Engineer shall inspect the excavation prior to it being backfilled.
c) Backfilling patch excavations
Excavations shall be backfilled with compliant pavement material for each layer as detailed in the Contract Documentation. The excavated material
shall be used when compliant or compliant material shall be imported. The backfilling shall be compacted to the specified density and finished to
the required levels for each layer. The base layer shall be finished to line and level to allow for the correct thickness of surfacing specified.
The Contractor shall place, mix and evenly spread the backfilling material into the patch excavation in individual layers and then compact each
layer to the specified density. The layers shall only be as thick as will successfully be compacted by the construction equipment being used. The
layer thickness shall not be less than twice the nominal maximum aggregate size in the backfilling material.
Where chemical stabilisation is specified the stabilising agent shall be added and mixed into the backfilling material in accordance with the
applicable specifications in Section A5.4.
Where emulsion treated base is specified for the base layer of the patch, the mix shall comply with Clause A4.1.5.15 of Chapter 4. The compliant
base material shall be placed in a concrete mixer or similar and mixed with water and a suitably diluted emulsion to achieve the required
compaction moisture content. Cement shall then be added while the mixing continues. Mixing shall continue until a uniform mix of the base
material, the bitumen emulsion and the cement is obtained.
Where asphalt base or bituminous surfacing material is specified as the wearing course for the completed patch, the preparation, mix design and
placement specification in Chapter 8 and / or Chapter 9 shall be applicable.
Use of a concrete mix or a soil cement mix to backfill a patch excavation shall not be permitted.
The level tolerances for patches are specified in Clause A5.5.8.3.
A5.5.7.2 Edge break repairs

This treatment shall be used for finishing off or repairing the edges of the surfaced area of a road. The repair is carried out so that the edges of
the repaired areas line up with the true edge of the original road surface or a newly surveyed edge as specified in the Contract Documentation.
Edge breaks shall be repaired in accordance with the patching specification in Clause A5.5.7.1 and as specified in the Contract Documentation.
Where asphalt base or bituminous surfacing material is specified as the wearing course for the completed edge break repair, the preparation, mix
design and placement specification in Chapter 8 and / or Chapter 9 shall be applicable.
A5.5.7.3 Treatment of exposed pavement layer

Where a pavement layer is excavated and removed using a milling machine or conventional construction equipment, the in-situ layer below shall
be inspected.
The cleaned surface shall be lightly sprayed with water to identify cracks. As the sprayed surface starts to dry, cracks dry out last making them
visible. The inspection shall take place by the Contractor along with the Engineer.
The Contract Documentation shall specify what treatment is required for exposed stabilised pavement layers and unstabilised pavement layers.
a) Stabilised exposed layer
All repairs shall be demarcated and carried out as specified.
Cracks shall be sealed as instructed by the Engineer and as specified in Sections A8.5 and A8.6 of Chapter 8.
Failed areas not caused by negligence on the part of the Contractor, shall be measured and paid for as a patch in accord with the size parameters
for a patch.
If the failed area is too large to be classified as a patch, it shall be measured and paid for as the reconstruction of a stabilised in-situ layer.
Reconstruction of the stabilised layer shall be carried out as per the applicable Clauses of A5.5.7.
Failed areas caused by negligence on the part of the Contractor during the excavation of the layer that was above shall be repaired by the
Contractor at no cost to the Employer.
Where specified, the application of a prime coat shall be carried out as specified in Section A8.1 of Chapter 8.

b) Unstabilised exposed layer
Where the exposed layer is unstabilised, the layer shall be inspected to establish the soundness of the layer. Any settlement cracks such as a
longitudinal crack shall be repaired by reconstruction of the layer in the vicinity of the crack or as instructed by the Engineer.
Material testing of the exposed layer such as in-situ density and CBR strength shall be carried out when instructed by the Engineer.
Failed areas not caused by negligence on the part of the Contractor, shall be measured and paid for as a patch in accord with the size parameters
for a patch.
If the failed area is too large to be classified as a patch, it shall be measured and paid for as the reconstruction of an unstabilised in-situ layer.
Reconstruction of the unstabilised layer shall be carried out as per the applicable Clauses of A5.5.7 or it can be compacted using roller-pass
compaction.
Failed areas caused by negligence on the part of the Contractor during the excavation of the layer that was above shall be repaired by the
Contractor at no cost to the Employer.
A5.5.7.4 In-situ pavement layer reconstruction preparation

Uniform pavement sections shall be clearly identified and detailed in the Contract Documentation.
In accord with these uniform sections an existing gravel layer or existing crushed stone layer may be reconstructed in-situ using a recycler or
using conventional construction equipment.
The preparation for the in-situ reconstruction, irrespective of the type of construction equipment used, shall be as specified in Clause A5.5.7.4a)
to g).
a) Establishing construction levels – minor level changes
Before commencing any in-situ reconstruction, the Contractor shall establish reference and level beacons for the setting-out and control of the
works.
When only minor level changes (less than 15 mm up or down) will be made to the existing vertical alignment and/or to the road cross-fall or
camber, in order to restore the riding quality of the road, then new road design levels will not usually be provided in the Contract Documentation.
At each level control location, the Contractor shall record the existing road surface levels at the centre-line and at the outer limits of each lane
including any surfaced shoulders. The Contractor shall use the existing road levels to determine the new construction levels along the centreline
and the outer limits of each traffic lane and any surfaced shoulders. A line of best fit shall be used to determine the final levels for the reconstructed
layer taking into account the following:
• Minimising the amount of preparatory work required ahead of reconstruction, such as minimising the importation of material.
• Additonal in-situ existing pavement material investigation
• The required design camber as specified in the Contract Documentation.
• The minimum cross-fall of 2 %.
• The minimum requirements governing changes in the vertical alignment.
• The thickness of the existing layer to be reconstructed.
At least two calendar weeks before reconstruction work is programmed (programme compiled in accord with Section A1.2 of Chapter 1) to
commence on any specific uniform pavement section, the Contractor shall submit the level proposals to the Engineer in sufficient detail to enable
the proposed reconstruction levels to be reviewed. The detail shall incorporate a schedule as well as a drawing, of all the design levels and the
grade lines. Once agreement has been reached regarding the proposed levels, reconstruction work may commence.
The Contractor shall establish a series of level control poles placed at a constant offset on both sides of the road prior to commencing any
construction work at a maximum interval as specified in Table A5.3.8-2. The Engineer shall take control measurements to determine the accuracy
and adequacy of the level control poles and shall instruct the Contractor to make any adjustments as required.
b) Establishing construction levels – significant level changes
When significant level changes (more than 15 mm up or down) will be made to the vertical alignment and/or to the road cross-fall or camber, the
reconstructed layers shall be reconstructed to new design levels provided in the Contract Documentation.
Before commencing any in-situ reconstruction, the Contractor shall establish reference and level beacons for the setting-out and control of the
works.
The Contractor shall survey the existing road levels and compare these with the new design levels and prepare a schedule of the areas where
there will be surplus material and of the areas where there will be insufficient material. This schedule will be used to prepare a layer material
transfer diagram which will enable the transfer of surplus reconstructed material to areas where there is a shortage of material. The material
transfer diagram shall be submitted to the Engineer for review at least two calendar weeks before reconstruction work is programmed (programme
compiled in accord with Section A1.2 of Chapter 1) to commence on any specific uniform pavement section.
The Engineer shall subsequently instruct the Contractor regarding the proposed reuse or spoil of surplus material, or the need to import any
additional new material prior to the commencement of the reconstruction work.
The Contractor shall establish a series of level control poles placed at a constant offset on both sides of the road prior to commencing any
construction work at a maximum interval as indicated in Table A5.3.8-2. The Engineer shall take control measurements to determine the accuracy
and adequacy of the level control poles and shall instruct the Contractor to make any adjustments as required.
c) Pre-milling the seal or asphalt surfacing
This construction work shall only be done using a milling machine.
Where specified in the Contract Documentation, pre-milling ahead of reconstruction shall be undertaken to remove isolated high spots or make
level adjustments more than 10 mm, normally at crest vertical curves, by accurate milling. The material resulting from such milling operations shall
be directly loaded onto trucks and disposed of as specified in the Contract Documentation.

d) Preparation of the road surface
Before any reconstruction work may commence, the surface of the existing road shall be prepared as follows:
• Remove all vegetation, dirt and other foreign matter including from any adjacent lanes or shoulders that are not to be reconstructed.
• Remove road studs from the full road width.
• Remove standing water.
• Establish an off-set reference line, for each cut, for the recycler to follow and ensure accurate steering.
• Record the location of all road marking features that will be obliterated by reconstruction.
• Rip and then grade off the asphalt or bituminous seal surfacing and take to spoil or stockpile as specified in the Contract Documentation
using conventional construction equipment.
• Use a milling machine to mill off the asphalt or bituminous seal surfacing and take to spoil or stockpile as specified in the Contract
Documentation.
• A bituminous seal may be left in place where specified in the Contract Documentation.
e) Pre-pulverising existing pavement layer material
Pre-pulverising or breaking down existing pavement material shall only be undertaken where specified in the Contract Documentation by ripping
or by using a milling machine or a recycler. Pre-pulverising shall be carried out to accomplish one or more of the following:
• Breaking down hard material prior to further processing with the recycler.
• Loosening the material across the road width so that it can be cross-mixed.
• To enable layer levels to be adjusted and/or to correct a road that is badly out of shape both in cross-section and long-section before
reconstructing/recycling the layer.
• The material in the existing pavement can be loaded and removed for direct use elsewhere or removed to stockpile or removed to spoil
where specified in the Contract Documentation. The exposed layer beneath may then be reconstructed in-situ where specified in the Contract
Documentation.
• To enable the removal of surplus material from areas where the vertical alignment is being lowered or the removal of material to spoil or to
stockpile prior to the commencement of the reconstruction operation.
The depth of pre-pulverising shall ensure that the cut horizon always remains at least 20 mm above the top of the pavement layer below which is
not being reconstructed and that this underlying pavement layer remains undisturbed.
Cross-mixing of the pre-pulverised material may be specified in the Contract Documentation or instructed by the Engineer.
The pre-pulverised material shall after shaping, be compacted to a minimum density of 93% MDD ahead of the in-situ pavement layer
reconstruction when using a recycler and shall receive one roller-pass using a smooth drum roller when using conventional construction
equipment.
f) Addition of imported material or make-up material
Imported material as specified in Clause A5.5.5.5 shall be spread on the pre-pulverised existing pavement layer prior to cross mixing and
subsequent reconstruction when required.
The placing and spreading of the imported material shall be such as to achieve the required reconstructed layer thickness and design levels for
the specific layer.
The compliant mixed existing and imported material shall be shaped and pre-compacted prior to the commencement of any reconstruction. This
ensures a firm surface for the recycler and the other equipment connected to the recycler to travel on.
g) Final preparations for the in-situ reconstruction process
No reconstruction work shall commence until the Contractor has confirmed that all the reconstruction construction equipment is in good working
order and is available alongside the particular section, to be reconstructed.
Where applicable the stabilisation mix design shall have been completed, and the types of agent and application rates thereof confirmed by the
Engineer to the Contractor. Sufficient quantities of the stabilising agents shall also be on the site. Where the cementitious agent is applied
mechanically or by hand on the reconstruction cut width, this shall be carried out as specified in Clause A5.4.7.
The following temperatures shall be measured and recorded to ensure compliance with the temperature-related specifications:
• Ambient air temperature.
• The temperature of the material in the reconstruction horizon.
• The temperatures of the bulk bitumen, the bitumen emulsion and the water in the respective tankers.
A5.5.7.5 In-situ pavement layer reconstruction

a) Final recycler construction equipment checks
The recycler shall be prepared for the first reconstruction cut. This shall include checking that:
• The mixing chamber is free of any material build-up that may reduce the efficiency of the cutting and remixing operation and that can affect
the functioning of the application nozzles on all relevant spray bars.
• The cutting drum is free of any material build-up that can reduce the efficiency of the cutting and remixing operation.
• The cutting tools are new or evenly worn across and around the cutting drum with sufficient remaining life to complete the first cut without
stopping.

• All relevant liquid application systems are functioning, free of blockages and that the in-line filters are clean. Where a bitumen stabilising
agent is applied, the check-sheet as provided in the Contract Documentation shall be completed and submitted to the Engineer.
• The on-board computer has been correctly set up and that the input data has been verified.
• The spray bar is set up with the correct nozzles selected to achieve the required width of application and in the case of further cuts the
nozzles across the 150 mm construction joint overlap are closed to prevent over-application of water and/or bituminous stabilisation agents.
• An off-set reference line is in place for the recycler to follow and is correctly aligned relative to the final road geometry.
• The depth of recycling has been confirmed and that all the equipment has been properly set to achieve this depth.
Where the primary compaction equipment is equipped with an integrated compactometer system it shall be checked to establish whether it is
working and that it has been set to record and print the correct data.
The bulk supply tanker/s shall be checked to ensure that they are coupled correctly to the recycler. Where stabilising agents are spread by hand
on the road surface ahead of the recycler it shall be carried out as specified in Section A5.4.
All feed pipes shall be properly connected, bled of air and free of leaks. In the case of bituminous stabilising work, the feed pipe shall only be
connected immediately before this work is about to start. Where the stabilising agent is foamed bitumen, the outlet pipes and valves on the bitumen
tanker shall be checked and any blockages cleaned out before connecting the feed pipe.
b) In-situ reconstruction using a recycler
The maximum allowable speed of advance of the recycler shall be 10 m per minute. The speed of advance of the recycler and the speed of
rotation of the recycling drum, shall be regulated to achieve:
• Adequate pulverisation of all bound materials in the existing pavement to produce a material that complies with the grading specification.
• Adequate mixing of all components to produce a homogenous material.
• A uniform and continuous application rate of liquid stabilising agent(s) and water at the specified application rates across the full width of
treatment.
(i) Layer dimensions
The depth of reconstruction shall coincide with the line and level specified for the lower horizon of the reconstructed stabilised layer.
The bottom of the cut horizon shall be checked at least once every 20 m of travel using a suitable T-bar to measure down from a
string line pulled between the final level reference marks on the level control posts.
An overlap width of 200 mm shall be maintained along all the longitudinal joints. The longitudinal line of cut shall not deviate laterally
by more than 50 mm from the operator’s off-set reference line that shall be positioned and then re-positioned for each and every
cut.
(ii) Mixing and placing the material
The mixing process shall be continuous with a minimum number of stops. Transverse joints that occur each time the recycler stops,
shall be properly treated to achieve continuity of stabilisation agent and moisture content across the joint.
The temperature across the entire width of material exiting the mixing chamber shall be checked every 100 m using a digital laser
thermometer held no more than 100 mm above the mixed material. Where the temperature varies by more than 3°C along a
particular longitudinal strip 200 mm wide, the recycler shall be stopped and the application nozzles on all the relevant spray bars
and nozzles that coincide with the deviant strip shall be checked for blockages.
As the mixed material exits from behind the recycler it shall be struck off by the rear door of the mixing chamber with sufficient
pressure applied onto the mixed material, to obtain a uniform surface that is free of valley lines, empty pockets and particle
segregation.
(iii) Primary compaction of the reconstructed material
A recycler is configured such that the rear wheels travel on top of the treated material along the outer extremities of the reconstruction
cut. Under no circumstances shall the reconstructed material be pre-shaped by grader prior to being compacted. To prevent
differential compaction across the width of the reconstruction cut, initial rolling to level the material between the recycler wheel tracks
shall be carried out with a recording pass of a steel drum roller in static mode (no vibration) and hence no compactometer readings
or any other readings are taken during this recording pass. Then the primary compaction process shall commence.
The primary compaction shall follow at the same rate of advancement as the recycler. Single vibrating smooth-drum rollers and/or
pad foot rollers shall be utilised to compact the reconstructed material. The rollers shall travel forwards and backwards at a constant
speed not exceeding 50 m per minute or 3 km/h, all the while remaining within the confines of the reconstructed cut.
Reconstructed material spilling over the outer extremities of the cut shall be cleared at regular intervals of about 5,0 m to expose
the cut line, thereby guiding the roller operator(s) to remain within the reconstructed cut width.
Successive lengths of mixed material, each approximately 50 m shall be compacted at a time. Rolling shall continue on each 50 m
section until the maximum achievable density has been reached. Where an integrated compactometer device is utilised, rolling shall
continue until the device indicates that no further improvement of density is occurring over at least 80 % of the length of the section.
The maximum achievable density has then been reached over at least 80 % of the section. Should the device indicate a consistent
loss of density at any one location, as indicated over two successive recording passes during primary compaction, compaction on
that section shall be terminated and the roller moved forward to start compaction of the next 50 m section.
To prevent differential compaction across the width of any reconstruction cut, primary compaction shall be completed prior to any
grader work commencing. A grader shall be used after completion of the primary compaction operation to cut the material down to
level. Sufficient reconstructed material depth shall be mixed and placed to ensure that there will be no low spots needing to be built
up during the cutting of levels. All low spots shall be reconstructed to the full depth of the reconstructed layer at no cost to the
Employer.
(iv) Secondary compaction and final levels
After completing the primary compaction on all adjacent cuts that make up the total width of pavement as reconstructed in a single-
operation, the surface shall be shaped and cut to level before secondary compaction is commenced. The moisture in the layer shall

be controlled during this process by applying light applications of water sprayed onto the exposed surfaces. No roller shall be allowed
onto the layer during this shaping process to prevent any lamination layers or biscuit layers from forming.
Secondary compaction comprising a minimum of three roller-passes shall then be commenced, using suitable smooth-drum
vibrating and/or pneumatic tyre rollers. Additional water may need to be sprayed onto the surface during this secondary compaction
operation in order to achieve a tight, well-knit surface finish. The smooth-drum rollers shall only operate in low amplitude vibration
mode.
Reconstructed material now flattened over the outer extremities of the cut shall be cleared at regular intervals of about 5,0 m to
expose the cut line, thereby guiding the roller operator(s) to remain within the reconstructed cut width.
(v) Slushing the reconstructed layer using water
When the secondary compaction and the cutting to level of the reconstructed layer is complete, the surface shall be slushed.
When no bitumen stabilising agent has been used in the reconstructed layer along with the chemical stabilising agent the slushing
shall commence by spraying the surface with water. Each spray of water shall be sufficient to completely wet the compacted surface
but without the water flowing off the surface of the compacted layer.
A pneumatic tyre roller shall then roll the wet surface in short sections between 40 m and 60 m long over the full width of the
reconstructed layer. The pneumatic tyre roller shall make sufficient passes and the surface must be sufficiently wet to generate a
small amount of fines in the form of slush and simultaneously close up small voids in the surface, close all grader-induced defects
and achieve a tightly knit surface finish without any biscuit layers.
Rolling with the pneumatic tyre roller shall continue until no free water is visible and a visually uniform surface appearance is
achieved. Hand held brooms or squeegees shall then move the slush over areas showing signs of roughness and/or segregation.
The squeegees or brooms shall be used to remove any surplus slush to the edge of the road surface. While still damp, the slush
shall be broomed, loaded and hauled to a designated spoil site at no cost to the Employer.
If a mechanically powered broom is used the surface shall not be damaged or loosened during the brooming process. The slushing
process must be completed on the same day that the stabilisation and reconstruction work is commenced.
Traffic shall not be permitted over the reconstructed layer.
Where the reconstructed layer is the base layer the final surfacing shall be placed prior to opening the road to traffic. The end
product of the slushing process is dependent on the material properties and therefore the desired surface finish must be established
during the construction of a trial section using the same material.
(vi) Slushing the reconstructed layer using bitumen emulsion
When the secondary compaction and the cutting to level of the reconstructed layer is complete, the surface shall be slushed.
When a bitumen stabilising agent has been used with or without a chemical stabilising agent in the reconstructed layer the slushing
shall commence by spraying the surface with bitumen emulsion.
A diluted bitumen emulsion at 15 % residual bitumen shall be applied at a rate of application between 0,5 ℓ/m2 and 0,75 ℓ/m2 for the
first application or as instructed by the Engineer. A water tanker fitted with an appropriate spraying system or a binder distributor
shall be used to spray a uniform amount of dilute emulsion on the surface before commencing with any rolling with a pneumatic tyre
roller. The first application and subsequent applications of bitumen emulsion shall be applied so as not to flow off the surface being
slushed. The amount of bitumen emulsion to be sprayed shall be confirmed during the construction of a trial section. Additional
diluted emulsion shall be applied until sufficient slush is generated under the wheels of the pneumatic tyre roller but before the
emulsion starts to break.
A pneumatic tyre roller shall be used to slush the wet surface. This shall be undertaken in short sections between 40 m and 60 m
long over the full width of the reconstructed layer. The pneumatic tyre roller shall make sufficient passes and the surface shall be
sufficiently wet to generate a small amount of fines in the form of slush and simultaneously close up small voids in the surface, close
all grader-induced defects and achieve a tightly-knit surface finish without any biscuit layers. Rolling should continue until a visually
uniform appearance is achieved. Rolling shall cease at the first indication that the emulsion shows of breaking and adhering to the
tyres of the roller.
Hand held squeegees or brooms shall continuously move the slush over areas showing signs of roughness and/or segregation. The
squeegees or brooms shall be used to remove any surplus slush to the edge of the road surface. While still damp, the slush shall
be broomed, loaded and hauled to a designated spoil site at no cost to the Employer.
If a mechanically powered broom is used the surface shall not be damaged or loosened during the brooming process. The slushing
process must be completed on the same day that the stabilisation and reconstruction work is commenced.
The end product of the slushing process is dependent on the material properties and therefore the desired surface finish must be
established during the construction of a trial section using the same material.
Traffic shall not normally be permitted over the reconstructed layer and the final surfacing shall preferably be placed prior to opening
the road to traffic. Where the intention is to open the finished layer to early trafficking the section of road shall remain closed to traffic
for a minimum period of 24 hours after completion. The moisture content of the layer shall also be checked after 24 hours and
provided it is below 80 % of OMC, the new layer may be opened to traffic when instructed by the Engineer.
Until a subsequent additional pavement layer or the surfacing is applied, the Contractor shall maintain the surface integrity of the
reconstructed layer. Maintenance personnel shall inspect all sections under traffic on a daily basis and take immediate action as
soon as any sign of surface ravelling is detected. Such action shall include the local application of dilute emulsion applied by hand
using a large paint brush, the application of a fog spray or patching with bituminous slurry or asphalt as appropriate.
c) In situ reconstruction using conventional construction equipment
The exposed in-situ gravel layer or crushed stone layer shall be scarified to the full depth of the existing layer or to the depth as specified in the
Contract Documentation when pre-pulverising has not been carried out. The scarified material shall then be broken down and all oversize material
removed. Excess material shall be loaded and removed for direct use elsewhere or removed to stockpile or to spoil.
Suitable material may also be added as specified in Clauses A5.5.5.5 and A5.5.7.3f).
All required stabilisation of the broken down material shall be done as specified in Clause A5.4.7.

The Contractor shall then process the layer in-situ as specified for pavement layers in Clause A5.3.7.
Slushing of the reconstructed layer shall be carried out as specified in Clause A5.5.7.5b), (v) and (vi).
A5.5.7.6 Reconstruction trial section

The Contractor shall construct an in-situ reconstruction trial section for each uniform section of pavement using the approved mix design
determined in accordance with the specifications in Clause A4.4.7 of Chapter 4. The uniform sections shall be as specified in the Contract
Documentation.
The Engineer may waive the need for a trial section for each uniform section, when the approved mix design and material types are similar for
each uniform section.
The Contractor shall follow the in-situ reconstruction process specified in Clause A5.5.7.3.
Prior to constructing the reconstruction trial section the Contractor shall assemble all items of construction equipment proposed to be used for the
trial section. Only the construction equipment items (conventional or recycler) that the Contractor intends using for production work shall be used
to construct the trial section and under no circumstances shall any substitutes be permitted.
The objectives of the trial section are as follows:
• To demonstrate that the construction equipment and the proposed process will enable the construction of the reconstructed layer in
accordance with the specified requirements in the Contract Documentation.
• To determine the effect on the grading of the reconstructed material by varying the advance speed of the recycler and the rate of rotation of
the milling drum.
• To determine how many roller-passes are required to achieve the specified relative compaction density.
• To confirm the finishing process methodology and confirm the required surface finish standard.
• To check the surface regularity of the base layer for compliance with Clause A5.3.8.5a).
• To determine the bulking factor of the reconstructed material, the size of the working windrow and the amount of material to be removed
after construction
A trial section shall be at least 150 m in length with a maximum of 200 m in length and shall cover the full lane width or partial road width in
accordance with the geometry of the road and the accepted work plan.
If the Contractor makes any alterations in the methods, processes, equipment or materials used, or is unable to consistently comply with the
specifications due to variations in the in-situ material or for any other reason, the construction of another trial section shall be required. If the first
trial section proves to be non-compliant a second trial section shall be constructed. The non-compliant first trial section shall be at no cost to the
Employer.
Reconstruction work may only commence once a trial section has been evaluated and certified compliant for a particular uniform pavement
section. Thereafter, it is the responsibility of the Contractor to obtain the necessary approval for the relevant mix design and any alterations to the
mix design that may be necessary for each uniform section ahead of the commencement of the reconstruction work.
To allow sufficient time to assess all aspects of the quality of the completed trial section and to ensure that the test results are compliant, the
Contractor shall programme to start the in-situ reconstruction work no sooner than 7 calendar days after constructing the trial section. The
Contractor shall have no claim for any programme delay caused by the construction of trial sections for whatever reason and the time required to
construct, test and approve the trial sections shall be allowed for in the approved construction programme.
A5.5.7.7 Curing reconstructed layers

The curing of chemically stabilised layers shall take place as specified in Clause A5.4.7.
No curing treatment is required for a bitumen stabilised layer when the layer has been slushed with a diluted bitumen emulsion.
A5.5.8 WORKMANSHIP
Any reconstructed layer with lamination layers or biscuit layers, as identified by the hollow sound caused when a heavy chain is dragged over the
compacted layer or when the layer is tapped with a geological hammer shall be rejected. The material in the rejected sections of the completed
layer shall be reconstructed in accord with the specifications or in accord with instruction from the Engineer. The layer shall be reconstructed prior
to the construction of any subsequent layers at no cost to the Employer.

The test results and measurements will be assessed in accordance with the provisions of Chapter 20: Quality Assurance.
A5.5.8.3 Construction tolerances for pavement layers

The individual reconstructed pavement layers shall comply with the construction tolerances for the appropriate layer as specified in Clause
A5.3.8.4. The surface regularity of a reconstructed base layer shall comply with the requirements of Clause A5.3.8.5a).
When a pavement layer of material is processed directly on top of a milled excavation floor (Clause A5.5.3.6), without the requirement that the
milled excavated floor first be trimmed to prescribed levels, the thickness tolerances shall not apply to the processed pavement layer on top
provided the compacted thickness of the layer on top is not less than 130 mm thick.
The final surface on any particular point on patches or between the patch and existing surface shall not deviate more than 5,0 mm from the bottom
of a 3,0 m long straight edge. The surface of the base layer of the patch shall match this tolerance taking into account that the maximum deviation
shall be 5,0 mm plus the proposed surfacing thickness.

A5.5.8.4 Material testing for reconstructed layer
Sample preparation and testing for bitumen stabilisation sampling and testing shall be in accordance with the latest edition of TG2.
The stabilised material sampled from the layer for the compaction of MDD briquettes, shall be prepared according to SANS 3001-GR54 and
compacted according to SANS 3001-GR31.
A5.5.8.5 Reconstructed layer process control

The Contractor shall establish a comprehensive process control system for the reconstruction work. This shall consist of a system of daily reports
submitted to the Engineer.
a) Pre-reconstruction report
This report shall comprise the following:
• The production and cut plans.
• The completed pre-start check list.
• Weather conditions and temperature measurements.
b) Post-reconstruction report
This report shall comprise the details of the reconstruction work completed during a single-operation with the following information for each
reconstruction cut (for a recycler) or reconstruction width (for conventional construction equipment):
• Start and end km value.
• Width and depth of cut including a schedule of dip measurements.
• Width of application of each stabilising agent.
• Nozzle settings and closures for each relevant spray bar.
• Computer data input.
• Number of primary compaction recording passes made.
• Primary compaction process control density records.
• Compaction data (including compactometer reading, vibration amplitude, advance speed of roller) in electronic format from the integrated
compactometer device fitted to the primary roller when applicable, at 2,0 m intervals.
c) Stabilising agent report
This report shall comprise details of the actual usage of stabilisation agent.
• Chemical stabilising agent spreading check measurements.
• Bitumen emulsion consumption.
• Straight bitumen consumption.
• Average temperature and pressure measured at the bitumen spray bar.
• All other details shown in the sample report included in the appendices of the latest edition of TG2.
d) Site diary report
This report shall comprise relevant information specifically concerning the reconstruction operation. These shall include but shall not be limited
to:
• Stoppage time and cause.
• Sections where in-situ pavement conditions changed from the documented uniform pavement section together with a description of the
change.
• Details of any non-routine tests undertaken.
• Any changes in the weather during the day.
• All site instructions received.
• The sampling location of the daily samples of pulverised or broken down material.

B5.5 RECONSTRUCTION OF PAVEMENT LAYERS
CONTENTS
B5.5.1 SCOPE
B5.5.2 DEFINITIONS
B5.5.3 GENERAL
B5.5.5 MATERIALS
B5.5.8 WORKMANSHIP
B5.5.1 SCOPE
This Section covers the work requirements for the reconstruction of existing road pavement layers. This comprises patching and in situ
reconstruction.
A relative large proportion of activities as defined in Part A under the various sections are therefore suitable for labour enhanced methods of
construction.
B5.5.2 DEFINITIONS
B5.5.3 GENERAL

B5.5.5 MATERIALS


For the reconstruction of pavement layers, patching and repair of edge breaks are suitable components for labour enhancement.
B5.5.8 WORKMANSHIP

C5.5 RECONSTRUCTION OF PAVEMENT LAYERS
(i) Preamble
otherwise stated.
handling, supervision, profit and liability costs to provide the services in the prime cost or provisional sum pay item.
(ii) Items not measured in this Section
deemed appropriate:
1. No additional payment shall be made for work in restricted areas.
2. Drainage and protection of the pavement layers from all damage that may occur for any reason until the Employer has taken over the works.
buildings, road signs, guard rails, street lights, fencing, service pipes or cables and any other items adjacent to, over or under the road that
could be damaged by the Contractor’s vehicles, construction equipment, or by public traffic being accommodated on or alongside the
pavement layers, during the construction of the pavement layers, until the Employer has taken over the works.
4. Repair of all damage to the existing pavement layers after access to the reconstruction site has been given to the Contractor and that may
occur before, during or after the construction of the reconstructed or rehabilitated pavement layers up until the Employer has taken over the
works.
5. Provision of additional material in excess of the compacted volume of the layers calculated using the layer dimensions given in the Contract
layers.
6. The removal of oversize material up to 5 % of the compacted layer volume.
7. Construction of tie in joints to new or existing road layers or surfacing.
8. The preparation and the inspection for cracks in an underlying layer after removal of a pavement layer.
9. Excavation of benches in pavement layers when widening an existing pavement
10. The provision and maintenance of covers for stockpiled reclaimed materials
11. The provision of method statements and of the programme of reconstruction work along with regular updates of the programme.
12. The brooming during the slushing process whether by hand or by mechanical means.
(iii) Items to be measured and paid for using payment items specified elsewhere in the specifications
Traffic accommodation A5.5.3.1
applicable items
C4.3 of Chapter 4 – All applicable
Reclaiming / removing layer material or surfacing A5.5.7.3c) and A5.5.7.4c)
items
Hauling materials such as:
• Surplus material from the works
• Import material from stockpile for specific layers Section C1.7 of Chapter 1 – All
Several references
• Import gravel material from Contractor quarry or applicable items
borrowpit
• Pre-milling material
Clearing and grubbing for reclaimed material stockpile sites A5.5.5.2
applicable items
Construction of stockpile site for materials designated for Sections C4.1, C4.4 of Chapter 4
A5.5.5.2
reconstruction including stabilisation and C5.4 – All applicable items
Crack sealing A5.5.3.6
applicable items
Surfacing of a patch or of an edge break A5.5.7.1 and A5.5.7.2
applicable items
C4.3 of Chapter 4 and Section C8.8
Saw cutting A5.5.7.1b)
of Chapter 8 – All applicable items
Stabilisation and agents A5.5.7.4 Section C5.4 – All applicable items

Processing of pavement layers with conventional
A5.5.7.4c) Section C5.3 – All applicable items
construction equipment
Curing a stabilised layer A5.5.7.6 Section C5.4 – All applicable items
Tack or prime a layer A5.5.3.6
applicable items
Chapter 8 and Chapter 9 – All
Surfacing a reconstructed layer Several references
applicable items
Providing a milling machine and milling A5.5.7.4c) and e)
applicable items
Material testing of exposed layer A5.5.7.3b) Item C4.3.1
(iv) Payment items specifically for this Section of the specifications

C5.5.1 Compiling and implementing M&U plans for the reconstruction of an existing road number (No)
pavement
The unit of measurement shall be the number of M&U plans for the reconstruction work. Several plans shall be required as specified in Clauses
A5.5.3.8 and A5.5.3.9.
The tendered rate shall include full compensation for gathering all information, compiling the plan(s) and for ensuring the implementation thereof
during the reconstruction work.
C5.5.2 Reconstruction preparatory work
C5.5.2.1 Undivided carriageway:
(a) Uniform section from km__________ to km __________ kilometre (km)
(b)
(a) Uniform section from km__________ to km__________ kilometre (km)
(c)
(b) Additional uniform sections kilometre (km)
C5.5.2.2 Divided carriageway:
(a)
(a) Uniform section from km __________ to __________ kilometre (km)
(b)
(b) Uniform section from km __________ to __________ kilometre (km)
(c)
(c) Additional uniform sections kilometre (km)
The unit of measurement shall be the kilometre of uniform section of road to be reconstructed and rehabilitated, measured along the centre-line
of the existing road. Each uniform section shall be measured separately. In the case of an undivided road carriageway this shall be measured
once along the centreline. In the case of a divided road carriageway this shall be measured once along each carriageway separately.
The tendered rates shall include full compensation for undertaking all the work required in preparation for reconstruction. This work includes all
survey and survey-related work such as setting out, checking the design levels and for preparing the information for submission to the Engineer
for approval of the final design levels.
The tendered rates shall also include for the removal of standing water, grass and weeds from the road surface including the shoulders.
C5.5.3 Construction equipment for sampling of in-situ material for mix design procedure number (No)
The unit of measurement shall be the number of positions for the sampling of in-situ material for the mix design procedure specified in Section
A4.4 of Chapter4
The tendered rate shall include full compensation for all costs to make available and to transport the recycler and other equipment to each sampling
position.
The tendered rate shall also include full compensation to provide the required traffic accommodation during the sampling process as specified in
the Contract Documentation
C5.5.4 Sampling of in-situ material for mix design procedure number (No)
The unit of measurement shall be the number of positions for sampling of in-situ material for the mix design procedure specified in Section A4.4
of Chapter 4.
The tendered rate shall include full compensation for all costs to operate the recycler and other equipment at each sampling position. This shall
include full compensation for breaking up the pavement for sampling and subsequent temporary patching of the sampled location by adding make-

up material, chemical stabilising agent, watering, compacting and surfacing the sampled area with a cold asphalt material or a hot asphalt mix or
a pre-manufactured seal patch.
The tendered rate shall include full compensation for all labour and other incidentals required for the sampling process and the subsequent delivery
of the samples to the testing laboratory.
C5.5.5 Construction of a trial section using a recycler cubic metre (m3)
The unit of measurement for the trial section using a recycler shall be the cubic metre of trial section constructed to the depth and width as
specified in the Contract Documentation. The quantity shall be calculated based on the cubic metre of the authorised dimensions of the trial
section. The trial section shall be at least 150 m long but no more than 200 m long.
The tendered rate shall include full compensation for setting out the trial section, preparing and providing the production plan for the trial section
specifically, preparing the existing road surface where required and breaking up the existing layer to the specified depth when this layer has not
been specified to be pre-milled or pre-pulverised. When specified, pre-milling or pre-pulverisation will be measured and paid for under item C5.5.7.
The tendered rate shall include breaking down the layer and preparing the material utilising a recycler, adding any extra water required and placing
the material followed by the primary and secondary compaction of the material all in accordance with Section A5.5. The rate shall include cutting
final levels to tolerance as well as the protection and maintenance of the layer and conducting process control and monitoring, for protecting the
adjacent pavement and for the repair thereof should it be damaged.
The tendered rate shall include full compensation for all labour, equipment and incidentals required to reconstruct the pavement layer as specified
The procurement, storage, spreading and mixing in of the chemical and/or bituminous stabilising agent for the stabilisation of the layer shall be
measured and paid for in accord with the relevant payment items of Section C4.4 of Chapter 4 and Section C5.4.
The tendered rate shall include full compensation for any cost incurred by the Contractor while awaiting the approval of the trial section.
C5.5.6 Construction of a trial section using conventional construction equipment cubic metre (m3)
The unit of measurement for the trial section using conventional construction equipment shall be the cubic metre of trial section constructed to the
depth and width as specified in the Contract Documentation. The quantity shall be calculated based on the cubic metre of the authorised
dimensions of the trial section. The trial section shall be at least 150 m but no more than 200 m long.
The tendered rate shall include full compensation for setting out the trial section, preparing and providing the production plan for the trial section
and preparing the existing road surface where required. Pre-milling or pre-pulverising of the existing pavement layer shall be carried out as part
of the layer preparation when specified in the Contract Documentation. Where specified, pre-milling or pre-pulverisation will be measured and
paid for under item C5.5.7.
The tendered rate shall include for processing, which shall include breaking down the material when no pre-milling or pre-pulverisation is specified
and for cutting final levels to the specified tolerances, all in accordance with Section A5.3. The tendered rate shall include the removal of up to 5
% oversize material by volume of the compacted layer. The tendered rate shall include the protection and maintenance of the layer, conducting
process control and monitoring and protecting the adjacent pavement from being damaged and for the repair thereof should it be damaged.
The tendered rate shall include full compensation for all labour, equipment and incidentals required to reconstruct the pavement layer as specified
The tendered rate shall include full compensation for any cost incurred by the Contractor while awaiting the approval of the trial section.
C5.5.7 Pre-milling existing wearing course material
C5.5.7.1 Pre-milling an asphalt wearing course (depth of pre-milling varies between 10 mm and 40 mm square metre (m2)
maximum).
C5.5.7.2 Pre-milling a seal wearing course (depth of pre-milling varies between 10 mm and 25 mm) square metre (m2)
The unit of measurement shall be a square metre of road surface pre-milled in accordance with the specifications. The quantity shall be
calculated based on the square metres of the actual pre-milling areas.
The tendered rates shall include full compensation for pre-milling ahead of reconstruction, for removing the isolated high spots with a minimum
milling depth of 10 mm and maximum milling depth of 40 mm or 25 mm for the asphalt wearing course or the seal wearing course respectively.
The tendered rates shall also include for directly loading and removing the milled material, for all plant movement over the site between isolated
high spots for providing all equipment, labour, supervision and incidentals for completing the work in accordance with the specifications.
The haul of the material shall be measured from the point of loading at the pre-milling section to the point of off-loading as per Section A1.7 of
Chapter 1.

C5.5.8 Pre-pulverising material in the existing pavement
C5.5.8.1 Asphalt wearing course (specify nominal depth) cubic metre (m3)
C5.5.8.2 Crushed stone base (specify nominal depth) cubic metre (m3)
C5.5.8.3 Stabilised crushed stone (specify nominal depth) cubic metre (m3)
C5.5.8.4 Stabilised gravel layer (specify nominal depth) cubic metre (m3)
The unit of measurement shall be the cubic metre of in-situ measured pavement layer that is pre-pulverised in-situ, regardless of the hardness or
type of material encountered in each pavement layer. The quantity shall be calculated from the measurement of the actual width and depth of the
layer that is pre-pulverised. The quantity shall not be adjusted to include any allowance for overlaps between adjacent cuts, nor for the number of
cuts required to cover the actual width of pre-pulverising.
The tendered rates shall include full compensation for setting out the works, for pre-pulverising each different type of material in the existing
pavement structure, for controlling the depth of pre-pulverising, for the addition of water whilst pre-pulverising, for mixing, placing, shaping, cutting
levels and compaction of the pulverised material as specified.
The tendered rates shall include full compensation for all transport, labour, equipment and incidentals required to pre-pulverise the material as
specified.
C5.5.9 Temporarily blading layer material to windrow cubic metre (m3)
The unit of measurement shall be a cubic metre of material from an existing pavement layer, temporarily bladed to windrow and measured in its
original position before removal.
The tendered rate shall include full compensation for temporarily blading the layer material to windrow and later blading the material back and
also for all clearing-up work which may be necessary after the material has been bladed back.
Only material bladed to windrow on the instruction of the Engineer in order to expose the underlying layer shall be measured and paid for.
Material removed and temporarily stockpiled, will not be paid for under this item.
C5.5.10 Roller-pass compaction of an exposed pavement layer
C5.5.10.1 Smooth drum vibratory rollers square metre (m2)
C5.5.10.2 Other vibratory rollers. (specify ____________) square metre (m2)
C5.5.10.3 Pneumatic-tyred rollers (PTR) square metre (m2)
C5.5.10.4 Other rollers. (specify _____________) square metre (m2)
The unit of measurement shall be the square metre of exposed pavement layer compacted in accordance with the specification for a single roller-
pass. The quantity will be measured in accordance with the authorised dimensions of the area to receive single roller-pass compaction.
The area to be roller-pass compacted shall be adjusted to be commensurate with the number of roller-pass compaction instructed. The authorised
area will be doubled when two roller-pass compaction is specified or trebled when three roller-pass compaction is specified in the Contract
Documentation, or instructed by the Engineer, and so forth.
The tendered rates shall include full compensation for shaping, providing the rollers, keeping the rollers operational and ready for when soil-
moisture conditions are favourable, and for compacting the pavement layer with the specified number of roller-passes.
The Contractor shall base the tendered rates on a single, one direction pass for each specified type, size and weight of roller. The area covered
by the nominal roller overlap width required to ensure full coverage of the area being compacted shall not be measured for additional payment. If
the rollers available on site are different types, sizes and weights than those specified in the Contract Documentation, then revised rates which
take into account the percentage increased or decreased compaction effort per roller-pass, shall be agreed with the Contractor based on the same
percentage increase or decrease.
The unit of measurement for the addition of water shall be the kilolitre of water applied as required.
The tendered rates for the addition of water to achieve the required compaction shall include full compensation for the supply, delivery and
application of the water when required.
C5.5.11 Watering the exposed pavement layer kilolitre (kℓ)
The unit of measurement shall be the kilolitre of water applied to the floor of the excavation that is to be compacted as per the instruction of the
Engineer, for roller-pass compaction only.
The tendered rate shall include full compensation for procuring and applying the water, including all transport costs of the water.

C5.5.12 Removal of surplus material from site cubic metre (m3)
The unit of measurement shall be the cubic metre of surplus material removed from site. The quantity shall be taken as 70 % of the loose volume
measured in the haulage trucks. Accurate truck records shall be kept on site and submitted to the Engineer on a daily basis.
The tendered rate shall include full compensation for gathering the surplus material by windrowing or pushing it into heaps, for loading and
transporting to a designated spoil or stockpile site for offloading and spreading or stockpiling the material.
The tendered rate shall include full compensation for all labour, equipment and incidentals required to remove the material as specified.
The haul of the recovered material shall be measured from the point of loading or collection to the point of off-loading as per Section A1.7 of
Chapter 1.
C5.5.13 Cross mixing of material (specify nominal depth) cubic metre (m3)
The unit of measurement shall be the cubic metre of material to be cross mixed, as instructed by the Engineer, to ensure lateral mixing of the
material. The quantity shall be calculated from the actual authorised dimensions of the finally cross mixed and compacted layer. The authorised
dimensions shall be as per the Contract Documentation or as instructed by the Engineer.
The tendered rate shall include full compensation for cross mixing, adding water and spreading the material.
The tendered rate shall include full compensation for all labour, equipment and incidentals required to complete the cross mixing as specified.
C5.5.14 In-situ reconstruction of a pavement layer using a recycler to construct a stabilised

selected layer
C5.5.14.1 Chemically stabilised selected layer compacted to 95 % of MDD:
(a) Using non-cemented material compacted to _________ mm thick cubic metre (m3)
(b) Using cemented material compacted to _________ mm thick cubic metre (m3)
(c) Using a combination of non-cemented and cemented material compacted to _________ mm cubic metre (m3)
thick
(d) Using pre-pulverised material (as per item C5.5.8) compacted to __________ mm thick cubic metre (m3)
C5.5.14.2 Emulsion stabilised selected layer compacted to 95 % of MDD:
(a) Using non-cemented material compacted to __________ mm thick cubic metre (m3)
(b) Using cemented material compacted to __________ mm thick cubic metre (m3)
(c) Using a combination of non-cemented and cemented material compacted to __________ mm cubic metre (m3)
thick
(d) Using pre-pulverised material (as per item C5.5.8) compacted to _________ mm thick cubic metre (m3)
C5.5.14.3 Foam stabilised selected layer compacted to 95 % of MDD
thick

subbase layer
C5.5.15.1 Chemically stabilised subbase layer compacted to 97 % of MDD:
thick

C5.5.15.2 Emulsion stabilised subbase layer compacted to 97 % of MDD:
thick
C5.5.15.3 Foam stabilised subbase layer compacted to 97 % of MDD
thick

base layer
C5.5.16.1 Chemically stabilised base layer compacted to 100 % of MDD:
thick
thick
thick
The unit of measurement for items C5.5.14; C5.5.15 and C5.5.16 above, shall be the cubic metre of in-situ reconstructed pavement layer, using
a recycler, the quantity of which shall be calculated in accordance with the authorised dimensions of the compacted layer.
The tendered rates shall include full compensation for setting out the works, preparing and providing the production plan(s) as per Clause
A5.5.8.5a), preparing the existing road surface where required and breaking up the existing layer to the specified depth.
The tendered rates shall include full compensation for breaking down the in-situ layer and preparing the material utilising a recycler, adding any
extra water required and placing of the material followed by the primary compaction and secondary compaction of the material. The rate shall
include full compensation for cutting final levels as well as the protection and maintenance of the layer, conducting process control and daily
monitoring, measuring and demarcating the work where layers are only partly reprocessed and for protecting the adjacent pavement and for the
repair thereof should it be damaged.
The tendered rates for items C5.5.14.1d), C5.5.14.2d) and C5.5.14.3d); items C5.5.15.1d), C5.5.15.2d) and C5.5.15.3d) and items C5.5.16.1d),
C5.5.16.2d) and C5.5.16.3d) shall also include full compensation for shaping and compacting the pre-pulverised material to 93% MDD.
The tendered rates shall include full compensation for the application of the bituminous stabilising agents in accord with the specifications of
Section A5.5.
The layer thickness to be stabilised can be varied by the Engineer by up to 20 mm, and the rate for this stabilisation work shall remain applicable.
The tendered rates shall also include for all labour, equipment and incidentals required to reconstruct the pavement layer.

measured and paid for in accord with the relevant items of Section C4.4 of Chapter 4 and Section A5.4.
C5.5.17 In-situ reconstruction of a pavement layer using conventional construction equipment

to construct a stabilised selected layer
C5.5.17.1 Chemically stabilised selected layer compacted to 95 % of MDD:
thick
C5.5.17.2 Emulsion stabilised selected layer compacted to 95 % of MDD:
thick
C5.5.17.3 Foam stabilised selected layer compacted to 95 % of MDD
thick

to construct a stabilised subbase layer
C5.5.18.1 Chemically stabilised subbase layer compacted to 97 % of MDD:
thick
thick
thick


to construct a stabilised base layer
C5.5.19.1 Chemically stabilised base layer compacted to 98 % of MDD:
thick
C5.5.19.2 Emulsion stabilised base layer compacted to 102 % of MDD:
thick
C5.5.19.3 Foam stabilised base layer compacted to 102 % of MDD
thick
The unit of measurement for items C5.5.17, C5.5.18 and C5.5.19 shall be the cubic metre of reconstructed pavement layer, using conventional
construction equipment the quantity of which shall be calculated in accordance with the authorised dimensions of the compacted layer.
The tendered rates shall include full compensation for setting out the works, preparing and providing the production plan(s) as per Clause
A5.5.8.5a), preparing the existing road surface where required and breaking up the existing layer to the specified depth when this layer has not
been specified to be pre-milled or pre-pulverised.
The tendered rates shall include full compensation for processing and compacting the in-situ material, which shall include breaking down any
oversize material, all in accord with Section A5.3 and cutting final levels to the specified tolerances. The tendered rates shall include full
compensation for the removal of up to 5 % oversize material by volume of the compacted layer as specified in the Contract Documentation. The
tendered rates shall include full compensation for cutting final levels. The tendered rates shall include full compensation for the protection and
maintenance of the layer, conducting process control and monitoring and protecting the adjacent pavement from being damaged and for the repair
thereof should it be damaged.
The tendered rates for items C5.5.17.1d), C5.5.17.2d) and C5.5.17.3d); items C5.5.18.1d), C5.5.18.2d) and C5.5.18.3d) and items C5.5.19.1d),
C5.5.19.2d) and C5.5.19.3d) shall also include full compensation for shaping and compacting the pre-pulverised material using one roller-pass
compaction with a static weight 15 ton smooth drum roller..
The layer thickness to be stabilised can be varied by the Engineer by up to 20 mm, and the rate for this stabilisation work shall remain applicable.
The tendered rates shall also include for all labour, equipment and incidentals required to reconstruct the pavement layer as specified in the
C5.5.20 Material shortfall or make-up material
C5.5.20.1 For selected layer cubic metre (m3)
C5.5.20.2 For subbase layer cubic metre (m3)
C5.5.20.3 For base layer cubic metre (m3)
The unit of measurement shall be a cubic metre of make-up material required on the instruction of the Engineer. The quantity will be determined
by way of cross-sections unless the Contract Documentation specifies that the quantity shall be taken as 70 % of the loose volume measured in
the haulage trucks.
The tendered rates shall include full compensation for procuring, adding and spreading the material over the existing pavement layer to be
reconstructed. The tendered rates shall include full compensation for levelling and pre-compacting the material when a recycler will be used to
carry out the reconstruction.
The haul of the make-up or shortfall material shall be measured from the point of loading or collection to the point of off-loading as per Section

A1.7 of Chapter 1. Material obtained from a commercial source shall include the haul.
C5.5.21 Finishing the stabilised layer
C5.5.21.1 Slush trial section with:
(a) Water square metre (m2)
(b) Diluted emulsion square metre (m2)
C5.5.21.2 Slush reconstructed section with:
(a) Water square metre (m2)
(b) Dilute emulsion square metre (m2)
C5.5.21.3 Application of a diluted emulsion spray litre (ℓ)
The unit of measurement for items C5.5.21.1 and C5.5.21.2 shall be the square metre of stabilised layer finished off by slushing with water or
diluted emulsion. The area shall be calculated from the authorised dimensions of the actual width and length of the stabilised layer so treated.
The tendered rates for items C5.5.21.1 and C5.5.21.2 shall include full compensation for the provision of all equipment, materials, labour and all
other incidentals to slush the layer as specified and for marking out the area to be slushed.
The unit of measurement for items C5.5.21.3 shall be the litre of diluted emulsion, measured at spraying temperature (see Chapter 8), applied in
accord with the Contract Documentation or as instructed by the Engineer.
The tendered rates for C5.5.21.3 shall include full compensation for the provision of all equipment, materials, labour and all other incidentals to
apply the diluted emulsion fog spray to the layer as specified. The tendered rates shall also include full compensation for marking out the area to
be sprayed with the diluted emulsion and for preparing the area as specified in Chapter 8.
The procurement, storage, handling and application of the bituminous emulsion for slushing or for spraying shall be measured and paid for under
the relevant items in Section C4.4 of Chapter 4 and Section C5.4 as part of the bituminous stabilising agent.
C5.5.22 Excavate pavement layers for patching in existing pavements
C5.5.22.1 Excavate the following layers:
(a) Asphalt layers with a surface area:
(a)
(i) Not exceeding 20 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(ii)
(b) Exceeding 20 m2 but not exceeding 50 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(iii)
(c) Exceeding 50 m2 but not exceeding 100 m2, including for edge repairs wider than 250 mm. cubic metre (m3)
(b) Cemented layers with a surface area:
(a)
(ii)
(b) Exceeding 20 m2 but not exceeding 50 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(iii)
(c) Exceeding 50 m2 but not exceeding 100 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(c) Any other layers (specify layer) with a surface area:
(d)
(ii)
(e) Exceeding 20 m2 but not exceeding 50 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(iii)
(f) Exceeding 50 m2 but not exceeding 100 m2, including for edge repairs wider than 250 mm. cubic metre (m3)
C5.5.22.2 Excavate the following layers using labour enhanced methods of construction:
(a) Asphalt layers with a surface area:
(g)
(ii)
(h) Exceeding 20 m2 but not exceeding 50 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(iii)
(i) Exceeding 50 m2 but not exceeding 100 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(b) Cemented layers with a surface area:

(d)
(ii)
(e) Exceeding 20 m2 but not exceeding 50 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(iii)
(f) Exceeding 50 m2 but not exceeding 100 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(c) Any other layers (specify type) with a surface area:
(j)
(ii)
(k) Exceeding 20 m2 but not exceeding 50 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(iii)
(l) Exceeding 50 m2 but not exceeding 100 m2, including for edge repairs wider than 250 mm cubic metre (m3)
The unit of measurement shall be a cubic metre of material excavated from the existing pavement including from the edge of the pavement for
edge repairs. The quantity shall be calculated in accordance with the authorised dimensions of the excavation.
The specified saw-cutting for the patch shall be measured and paid for under Section C4.3 of Chapter 4.
The tendered rates shall include full compensation for demarcating the excavation, excavating the material, placing the excavated material in
temporary stockpiles, for loading the material into haul trucks and for spoiling the material at a designated spoil site.
Payment shall distinguish between the different types of pavement material excavated as described in this item.
The haul of the excavated material shall be measured from the point of loading or collection to the point of off-loading as per Section A1.7 of
Chapter 1.
Distinction shall be made in respect of the method of construction specified. Where the excavation of material is specified by means of labour
enhancement methods, the tendered rates shall include wheelbarrow transport over a free haul distance of 50 m.
C5.5.23 Edge break cutting back when narrower than 250 mm
C5.5.23.1 Edge break cutting back when narrower than 250 mm metre (m)
C5.5.23.2 Edge break cutting back when narrower than 250 mm using labour enhanced methods of metre (m)
construction
The unit of measurement for cutting back the edges shall be the metre of pavement edge cut back and excavated as specified and measured
parallel to the road centreline. This item shall only apply to edge breaks of which the finally repaired width is less than 250 mm.
The tendered rates for cutting back the edge shall include full compensation for demarcating the edge repair cutting the edge to the line as
specified in the Contract Documentation or as instructed by the Engineer, excavating the material to the specified depth and for loading all
excavated and loose material and hauling to spoil.
The tendered rates shall also include full compensation for labour, material, and all incidentals necessary for completing all the work in accordance
with the specifications.
The haul of the excavated material shall be measured from the point of loading or collection to the point of off-loading as per Section A1.7 of
Chapter 1.
Distinction shall be made in respect of the method of construction specified. Where the cutting back of edge break is specified by means of labour
enhancement methods, the tendered rates shall include wheelbarrow transport over a free haul distance of 50 m.
C5.5.24 Edge break patching when narrower than 250 mm
C5.5.24.1 Edge break patching using emulsion treated base (ETB) material to a maximum depth of 150 metre (m)
mm
C5.5.24.2 Edge break patching using labour enhanced methods of construction and (ETB) to a maximum metre (m)
depth of 150 mm
The unit of measurement for patching the edges shall be a metre of pavement edge patched as specified and measured parallel to the road
centreline. This payment item shall only apply to edge breaks of which the finally repaired width is less than 250 mm.
The tendered rates for reconstructing pavement edges shall include full compensation for compacting the exposed pavement layer surface on which
the new edge is to be constructed.
The tendered rates shall also include full compensation for procuring, furnishing and mixing all materials as specified for ETB material in Clause
A4.1.5.14 of Chapter 4, for use in the edge break patch and then placing, compacting and trimming the material to the required lines and levels as per
the Contract Documentation or as instructed by the Engineer.
The tendered rates shall also include full compensation for loading the material into haul trucks, handling, labour, material, and all incidentals
necessary for completing all the work in accordance with the specifications.
Measurement and payment for the prime and asphalt surfacing for the edge repair shall be made as specified in Chapter 9.
The haul of the excavated material and of the material for the ETB shall be measured from the point of loading or collection to the point of off-

C5.5.25 Compacting the floor of the excavation for patching square metre (m2)
The unit of measurement shall be a square metre of excavation floor compacted and the quantity shall be computed in accordance with the
authorised dimensions of the excavation floor.
The tendered rate shall include full compensation for compaction of the floor of the excavation as specified in the Contract Documentation. Payment
shall not distinguish between the various methods of compaction or various density requirements.
C5.5.26 Backfill patching excavations in existing pavements
C5.5.26.1 Backfill with the following pavement layer material:
(a) Chemically stabilised pavement layer material (specify the pavement layer, the material source
being from commercial or from stockpile, the % stabilising agent and the % of MDD) for a patch
with a surface area:
(m) Not exceeding 20 m2, including for edge repairs wider than 250 mm
(i) cubic metre (m3)
(ii)
(n) Exceeding 20 m2 but not exceeding 50 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(o) Exceeding 50 m2 but not exceeding 100 m2, including for edge repairs wider than 250 mm
(iii) cubic metre (m3)
(b) Emulsion treated base, or ETB pavement material (specify the pavement layer, the material
source being from commercial or from stockpile, the components as per Clause A4.1.5.14,
and the % of MDD) for a patch with a surface area:
(p)
(ii)
(q) Exceeding 20 m2 but not exceeding 50 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(iii)
(r) Exceeding 50 m2 but not exceeding 100 m2, including for edge repairs wider than 250 mm. cubic metre (m3)
C5.5.26.2 Backfill with the following pavement layer material using labour enhanced methods of
construction:
(a) Chemically stabilised pavement material (specify the pavement layer, the material source
being from commercial or from stockpile, the % stabilising agent and the % of MDD) for a patch
with a surface area:
(s)
(ii)
(t) Exceeding 20 m2 but not exceeding 50 m2, including for edge repairs wider than 250 mm cubic metre (m3)
(u) Exceeding 50 m2 but not exceeding 100 m2, including for edge repairs wider than 250 mm.
(iii) cubic metre (m3)
(b) Emulsion treated base, or ETB pavement material (specify the pavement layer, the material
source being from commercial or from stockpile, the components as per Clause A4.1.5.14,
and the % of MDD) for a patch with a surface area:
(v)
(w) Exceeding 20 m2 but not exceeding 50 m2, including for edge repairs wider than 250 mm
(ii) cubic metre (m3)
(iii)
(x) Exceeding 50 m2 but not exceeding 100 m2, including for edge repairs wider than 250 mm. cubic metre (m3)
The unit of measurement shall be a cubic metre of the specified material placed and compacted in accordance with the specified requirements in
the Contract Documentation. The quantity shall be computed in accordance with the authorised dimensions of the layer.
The tendered rates shall include full compensation for providing all the compliant material for the specific layer, irrespective of the origin thereof,
for all mixing, including mixing all components as specified for ETB material in Clause A4.1.5.14 of Chapter 4, placing, compacting to the specified
density and finishing, and also for all machinery, equipment, labour, supervision and other incidentals for executing the work as specified.
The procurement, spreading and mixing of stabilising agents shall be measured and paid for under Section A4.4 of Chapter 4 and Section A5.4.
Measurement and payment for the prime and asphalt surfacing for the patch shall be made as specified in Chapter 8 and/or Chapter 9.
The haul of the material for the various backfill layers shall be measured from the point of loading or collection to the point of off-loading as per
Section A1.7 of Chapter 1. The tendered rates for backfilling with commercial material shall include all the transport costs of the commercial
material.
Distinction shall be made in respect of the method of construction specified.

D5.5 RECONSTRUCTION OF PAVEMENT LAYERS
CONTENTS
D5.5.1 SCOPE
D5.5.2 GENERAL

South Africa
COTO
Officials


October 2020

FOREWORD

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TABLE OF CONTENTS
CHAPTER 6: CONCRETE LAYERS ....................................................................................................................... 6-1
6.1 PAVER LAID CONCRETE LAYERS ................................................................................................................. 6-1
6.2 SEGMENTAL BLOCK PAVING LAYERS ....................................................................................................... 6-27

6.1 PAVER LAID CONCRETE LAYERS
CONTENTS
A6.1.1 SCOPE
A6.1.2 DEFINITIONS
A6.1.3 GENERAL
A6.1.5 MATERIALS
A6.1.8 WORKMANSHIP

A6.1 PAVER LAID CONCRETE LAYERS

A6.1.1 SCOPE
This Section covers all the material requirements and work pertaining to the construction of mechanically paver laid concrete layers on new
supporting layers or existing concrete or asphalt layers and include, inter-alia, the following pavement types:
- Jointed concrete pavement (JCP- Plain) – with or without dowels, for new construction or overlays
- Continuously reinforced concrete (CRCP) for new construction or overlays
It includes, inter alia, the specifications for materials, manufacture and construction requirements as relevant to the specific pavement as
prescribed.
This Chapter does not apply to the repair and or rehabilitation of concrete pavements, which is covered in Chapter 7: Maintenance and Repair of
Concrete Layers. The construction of concrete pavements utilising labour based methods or relatively small or isolated sections of concrete
pavement are covered in Part B of this Chapter.
A6.1.2 DEFINITIONS
Jointed Concrete Pavement (Plain JCP) - concrete pavements that contain sufficient joints to control all expected natural cracks. All necessary
cracking occurs at joints and not elsewhere in the slab. However, there may be load transfer devices (e.g. dowel bars) at transverse joints and
deformed steel bars (e.g. tie bars) at longitudinal joints, which are not considered as reinforcement.
Continuously Reinforced Concrete Pavement (CRCP) - concrete pavements that include continuous longitudinal reinforcement steel typically
between 0,50 and 0,70 % of the cross-sectional area of the pavement slab. They also typically include transverse reinforcing consisting of
individual bars placed at approximately 1,0 m intervals or as specified in the Contract Documentation.
Aggregate - granular material of natural, manufactured or recycled origin used in the manufacture of concrete products to the specific grade/class
as defined in these specifications and the latest published version of SANS 1083, or as may be otherwise specifically specified in the Contract
Documentation:
- Course aggregate – all aggregate > 5,0 mm as further defined in the latest SANS 1083 specification for the specific class of aggregate and
nominal maximum aggregate size as required.
- Nominal maximum particle size (NMPS) – designated as one sieve size larger than the largest sieve to retain a minimum of 15 % of the
aggregate particles.
- Fine aggregate – all aggregate fractions ≤ 5,0 mm and which shall consist of clean material derived from crushing competent parent rock,
or naturally occurring sand conforming to SANS 1083 and any further specified requirements listed herein.
Cement - as defined in SANS 50197-1 for the various classes as listed.
Cement extenders or supplementary cementitious materials - the following as defined in the relevant SANS documents:
- Ground Granulated Blast Furnace Slag: As defined in SANS 55167-1

- Fly Ash: As defined in SANS 50450-1
Characteristic compressive strength - characteristic strength of concrete is the compressive cylinder or cube strength below which no more
than 5 % of the test results in a statistical population shall fall, tested as specified in SANS 3001-CO 1and 2.
Valid test result (Fcu) - a valid test result, for the purpose of evaluating compressive strength, shall comprise of the arithmetic mean of three cube
or cylinder specimens where the difference between the highest and lowest result does not exceed 15 % of the arithmetic mean of the specimens.
Water: cementitious binder ratio - the ratio of the total water content to total cementitious binder content by mass in the mixed concrete.
A6.1.3 GENERAL
A6.1.3.1 Quality Plan
Prior to commencing with any permanent works, the Contractor shall submit a Quality Plan, for review and acceptance by the Engineer, detailing
all checks and hold points relating to construction of the specified product. All work shall be completed in accordance with accepted Plan, with
any deviations resubmitted to the Engineer for evaluation and acceptance prior to implementation thereof.
A6.1.3.2 Trial sections

Where so provided for in the pricing schedule, the Contractor shall construct a trial section for each pavement type specified. The location and
area of the trials in an area that simulates the permanent work condition shall be as directed by the Engineer. The purpose of the trial is for the
Contractor to demonstrate that the equipment, processes and intended concrete mix that he proposes to use will enable him to construct the
particular concrete layer in accordance with all the specified requirements. Evaluation and monitoring of the trial section shall include all items
listed in the South African Pavement Engineering Manual (SAPEM), Chapter 12 Appendix, Table 19: Concrete Pavement Trial Section Checklist.
The Contractor shall calibrate the equipment and refine the mix design and construction process at his own cost.
The Contractor may, unless advised of any deficiencies in the trial section, proceed with the construction of the pavement ten days after the completion
of the trial section or such earlier time as the Engineer may determine. In the event of deficiencies in the trial section, the Engineer may order the
Contractor to construct a further trial section, which shall again be regarded as the initial trial section with no additional cost. The Contractor may then
proceed with the construction of the pavement ten days after the satisfactory completion and acceptance of the second or subsequent trial section.
If the Contractor should make any alterations in the methods, processes, equipment or materials used and approved, or if he is unable to comply
consistently with the specifications, the Engineer may require that a new trial section be constructed, at the Contractor's cost, before allowing the
Contractor to continue with any permanent work. The intention of this clause is to avoid any experimentation by the Contractor on the permanent
work.
The trial sections shall be laid where indicated by the Engineer. The Contractor shall prepare the surface on which to lay the trial section and
shall also, if required, remove the trial section after completion and restore the surface on which it was constructed, all at the Contractor's cost.
Provision is made for payment of the first approved trial section of any particular mix type, but subsequent trial sections that may be required for
the same mix type shall be at the Contractor's own cost. Payment will be made for the specified area of each approved first trial section for any
particular mix type.
A6.1.3.3 Weather limitations

a) Responsibility for protection
The Contractor shall be responsible for the quality and strength of the concrete placed and for its protection. Any concrete damaged by adverse
weather, such as, any combination of high or low ambient temperature, low humidity, wind, rain and hail, shall be removed and replaced at the
Contractor's expense.
b) Protection against rain or hail
No concrete shall be placed during rainy weather. For the concrete to be properly protected against rain and hail before it has sufficiently hardened,
the Contractor shall have available at all times frame-mounted waterproof covers for protecting the surface of the unhardened concrete. In addition,
when slip-form pavers are used, the Contractor shall also provide acceptable emergency protection for the slab edges. When rain appears to be
imminent, all paving operations shall cease and the Contractor shall take the necessary steps to protect the unhardened concrete. The Contractor
shall be responsible for the repair of any damage to the concrete, texturing or the curing compound that may occur.
c) Cold-weather paving
All reasonable precautions shall be taken to prevent the temperature of the pavement concrete from falling below 5C during the first 48 hours
after casting. When prevailing temperatures are low, or when cold weather is forecast and there is a danger that the temperature of the freshly
constructed concrete pavement will fall below the prescribed limits the Contractor shall either cease all pavement operations, or he may be
permitted to proceed, provided that the Engineer is satisfied that adequate protective measures are available and will be taken to ensure that the
temperature of the pavement will be maintained above 5C for the period stated.
d) Hot-weather paving
When paving is done during hot weather and when the temperature of the fresh concrete can be expected to exceed 24C, the Contractor shall
implement appropriate precautionary measures to place the concrete at the coolest temperature practicable. Paving operations shall cease when
the concrete temperature as discharged at the paver exceeds 32C.
e) Hot and windy weather paving
Unless appropriate and adequate protection measures to the plastic concrete are provided, all production of concrete and paving operations shall
cease when the prevailing evaporation rate, as determined in accordance with the nomograph given in Clause A 20.1.5.15 of Chapter 20 exceeds
1,0 kg/m²/hr.
Provision has been made in the Pricing Schedule in Chapter 1 for the establishment of a portable weather station to be located in the immediate
vicinity of the paving site and positioned at 1,0 m above the level of the pavement being constructed. During paving operations the Contractor
shall provide the Engineer with all the relevant data as recorded by the weather station.

A6.1.4.1 General
The Contractor shall be responsible for providing suitable materials as prescribed in Clause A6.1.5, determining the mix proportions, and
manufacturing the concrete of the required quality and consistency.
The specifications prescribed for materials to be used for concrete shall not limit the Contractor's responsibility to design and manufacture concrete
which complies with the requirements of these specifications. If the Contractor finds it necessary to work to more stringent tolerances than those
specified, or that the aggregates have to be further processed in any way (e.g., by washing or sieving) to permit, or to facilitate, paving operations,
all costs resulting therefrom shall be for the Contractor's account. However, if the Contractor is of the opinion that the requirements of the
specifications regarding the materials to be used will prevent him from manufacturing concrete of the required quality, he shall submit the
necessary supporting evidence to the Engineer. If such evidence is acceptable to the Engineer, he may amend certain requirements of the
materials specification.
A6.1.4.2 Design requirements

a) Water-cement ratio
The water-cement ratio shall not exceed 0,53.
b) Minimum cement content
The total cementitious content of the mix shall be not less than 320 kg/m3.
c) Specified strength
The relationship between the 28-day cube compressive and the 28-day flexural of the concrete shall be established by laboratory tests.
The specified compressive strength shall be the highest of the following four values:
(i) 35 MPa at 28 days; or
(ii) 0,85 fc1 where fc1 is the 28-day compressive strength corresponding to a 28-day flexural strength of 4,5 MPa.
(iii) 0,85 fc2, where fc2 is the 28-day compressive strength corresponding to a water: cement ratio of 0,53.
(iv) 0,85 fc3, where fc3 is the 28-day compressive strength corresponding to a cement content of 320 kg/m3.
Where fc1, fc2 and fc3 shall be the 28-day compressive strengths determined from laboratory mixes as prescribed in Clause A6.1.4.3.
d) Workability of the concrete

The mix proportions and consistency of the concrete mix shall be such that, with the equipment in use, the concrete can be adequately transported,
discharged, and fully consolidated without excessive bleeding or segregation of the components. The concrete consistency shall be appropriate
to the type of paving equipment used, the haul, the weather and the site conditions. Where consistency is measured by way of a slump test in
accordance with SANS 3001-CO1-3, the slump shall not deviate by more than 20 mm from the optimum value for mixes with a target slump of 35
mm or greater.
Where the required consistency of the concrete is such that the desired slump is less than 35 mm, the consistency of the concrete shall be
determined by means of the Vebe test in accordance with SANS 3001-CO1-4.
e) Air content
Where an air-entraining agent is prescribed in the Contract Documentation, the total air content in the freshly mixed concrete shall be M ± 1 %,
where M is the target value within the limits of 2 % to 4 %. Tests shall be conducted in accordance with SANS 3001- CO1-8.
A6.1.4.3 Design procedure

a) General
The proportions of cement and aggregate required for producing concrete which complies with the requirements of these specifications shall be
determined by means of laboratory tests on concrete manufactured from the cement, coarse and fine aggregates, admixtures (if any) and water
proposed for use in the works.
b) Preliminary tests
At least thirty days prior to the construction of the trial pavement, as specified in Clause A6.1.3.2, the Contractor shall submit to the Engineer
samples of all the components of the concrete he proposes to use, together with a report by an approved testing laboratory showing the mix
proportions proposed for each combination of material sources for the concrete. The report shall also include the following:
(i) The results of tests on the specified properties of all components.
(ii) The relationship between the 28-day compressive strength and flexural strength of the concrete at each of at least three water cement ratios
namely 0,48; 0,53 and 0,58.
(iii) The effect of the particular admixture (if any) proposed by the Contractor in regard to variations in admixtures, air content (if air entraining),
concrete setting and sawing times.
(iv) The effect of at least three water contents on concrete consistency.
In determining the relationship between compressive and flexural strength, the tests shall be based on not less than six compressive-strength
specimens and six flexural-strength specimens for each water-cement ratio. All tests shall be conducted in accordance with the methods in SANS
3001 CO1, SANS 3001 CO2 and SANS 3001 CO3 as relevant.
c) Changes in the mix proportions or the materials
(i) If during the progress of the work the requirements set out in Clause A6.1.4.2 are not being met by concrete manufactured from the materials or
material mix proportions as approved, the Contractor shall immediately cease producing such concrete and shall effect such changes to the mix
proportions and/or materials as may be necessary in order to meet those requirements.

(ii) If during the progress of the work the Contractor wishes to use materials or mix proportions other than those originally approved, or if the materials
from the sources originally approved change with regard to any properties, he shall, before proceeding with further work, submit adequate
evidence to the Engineer that the new materials or combination of materials will produce concrete which complies with the requirements of
Clause A6.1.4.2 and shall not bring about any detrimental changes in the properties of the concrete.
(iii) Any such changes made shall be at the Contractor's expense, and no extra payment shall be allowed for reason of such changes.
(iv) Where concrete is required to be placed, vibrated or finished with hand equipment for any specific reason, the requirements of Clause A6.1.4.2
shall remain applicable irrespective of the size of the concrete panel or concrete patch placed. The mix proportions, however, shall be adjusted
to promote hand placing, vibrating and finishing, but only if the Contractor has produced written proof to the Engineer that the requirements of
Clause A6.1.4.2 cannot be complied with under the specific circumstances.
d) Changes in requirements
The Engineer shall have the power, at any time during the progress of the work, to order changes in the requirements set out in Clause A6.1.4.2.
In such cases the Contractor shall be compensated in accordance with the terms of the contract for the additional cost of materials or additional
handling, placing and/or other costs, if any, resulting from such changes. If such changes result in savings, the Engineer shall recover such savings
from the Contractor.
e) Mix designs
The mix design requirements as specified in Clause A1.2.5.2 will also apply. Testing for mix designs shall be performed by laboratories
accredited by SANAS for the relevant tests.
A6.1.5 MATERIALS
A6.1.5.1 Cementitious materials
The cementitious materials used for concrete shall comply with the following standards:
- Cement shall comply with SANS 50197-1 (EN 197-1) with a strength class of 32,5 or greater, and a rate of strength gain N or greater.
Cement shall hold valid certification in the form of a Letter of Authority issued as certified approval pursuant to the Compulsory Specification
for cement published by Government Notice R.544. Masonry cement shall not be used. The cement type and class incorporated in the mix
shall be appropriate to the type of pavement to be constructed and the placing, finishing and saw cutting constraints envisaged.
- Ground Granulated Blast Furnace Slag - SANS 55167-1
- Fly ash - SANS 50450-1
Blends of cement complying with SANS 50197-1 and supplementary cementitious materials complying with the above standards may be used
subject to a maximum of 20 % of the total cementitious content.
In order to promote resource sustainability principles, cement shall have a maximum average carbon dioxide emission value of 925 kg CO2e per
ton, determined in accordance with the World Business Council for Sustainable Development Greenhouse Gas Protocol.
All cementitious materials shall be protected from moisture until used, and there shall be sufficient facilities to ensure that the cementitious
materials to be used in the work are kept separate from each other and from other cementitious materials.
Where cementitious materials are stored in a silo, the silo must be emptied before using the silo for a different cementitious material. Blended
cements with a percentage of SCM differing by more than 2 % shall be considered different cementitious materials.
The cementitious binder shall comprise either cement, complying with SANS 50197-1, or an approved site blend of such cement and
supplementary cementitious materials that take appropriate cognisance of environmental conditions, durability and strength requirements. The
site blending of cement with supplementary cementitious materials shall only be conducted on the basis of an acceptable quality assurance
system approved by the Engineer.
A6.1.5.2 Water
Water for washing aggregates, mixing concrete, and curing shall comply with relevant requirements specified in SANS 51008.
A6.1.5.3 Aggregates for concrete

a) General
Aggregates shall not contain any deleterious quantities of organic material, particularly pieces of timber, grass or similar matter as assessed by visual
inspection, which will cause unacceptable surface defects when they float to the top of fresh concrete during vibration. Aggregates shall comply with
the requirements of SANS 1083 for concrete but subject to the following:
The average 28 day drying shrinkage of 3 concrete samples made from each of the required three concrete mixtures for preparing the compressive-
strength and flexural-strength samples in accordance with Clause A6.1.4.3 shall not exceed 0,040 %. Drying-shrinkage tests shall be conducted in
accordance with SANS 3001-CO2-7. Where the drying shrinkage exceeds the specified maximum value, either alternative aggregates shall be used,
further investigations undertaken, or evidence shall be produced with a view to confirming the suitability of the aggregates proposed for use. The
historical behaviour of the aggregate in concrete may serve as a recommendation in such cases if accepted by the Engineer.
b) Alkali-aggregate reaction
Where there is any risk of a particular combination of aggregate and cement giving rise to a harmful alkali-aggregate reaction, the proposed
combination shall be tested in accordance with SANS 6245 (SANS3001- AG 46). Where the result indicates such potential reaction, the aggregate,
shall be replaced so that an acceptable combination may be obtained.

c) Coarse aggregate
(i) Hardness
When tested in accordance with SANS 3001 No AG10, the 10 % FACT value shall comply with the following requirements:
10 % FACT Dry - 210 kN minimum: Wet – 160 kN minimum.
(ii) Flakiness Index

The flakiness index of the coarse aggregate, as determined in accordance with SANS 3001 – AG4 shall not exceed 35.
(iii) Nominal Maximum Particle Size (NMPS)
The maximum nominal particle sizes of the coarse aggregate fraction in the mix shall be as follows:
- Slab thickness >175 mm: 37,5 mm, plus one or more of the following 20,0 mm, 14,0 mm and 10,0 mm.
- Slab thickness >150 mm < 175 mm: 28,0 mm (Where recommended by an approved laboratory and approved by the Engineer, smaller
sizes of aggregate, nominal 20,0 and/or 14,0 mm sizes shall be provided).
- Slab thickness >100 mm <150 mm: 20 mm (Where recommended by an approved laboratory and approved by the Engineer, smaller
sizes of aggregate, nominal 14,00 and/or 10,0 mm sizes, shall be provided).
- Slab thickness <100 mm: 14,0 mm (Where recommended by an approved laboratory and approved by the Engineer, smaller sizes of
aggregate, nominal 10,0 mm and/or 7,1 mm shall be provided).
d) Fine aggregate
The fine aggregate shall be either a natural or crusher-produced sand or a blend of natural and crusher sands. Where a mixture is used, and the
quantity passing through each of the 0,150 mm and 0,075 mm sieves shall not exceed the relevant interpolated values for the approved blend. Where
required by the Engineer the fine aggregate shall contain more than 20 % quartz by mass.
The acid insolubility of the fine aggregate, or fine aggregate blend, as determined in accordance with SANS 642, shall exceed 40 %.
The fineness modulus (FM), as determined in accordance with SANS 3001 AG-1 and PR-5, FM of the fine aggregate (or mixtures thereof) shall not
deviate from the approved fine aggregate component (or mixtures thereof) by more than 0,20.
e) Additional requirements for aggregates
Where instructed by the Engineer, aggregates shall be checked and shall be free of the following deleterious substances:
(i) Tests for the presence of sugar shall be determined in accordance with SANS 3001-AG-30 (SANS 5833) and shall be free from the presence
of sugar;
(ii) Tests for soluble deleterious impurities shall be conducted in accordance with SANS 3001-AG-31 (SANS 5834) and shall have minimum
compressive strength of 85 % of the reference;
(iii) Test for the presence of material of low density shall be determined in accordance with SANS 3001-AG-?? (SANS 5837) and shall have
maximum 0,5 % by mass;
(iv) Tests for soluble salts shall be determined in accordance with SANS 3001-AG-40 (SANS 5849) and shall have maximum 0,5 % by mass;
(v) Tests for water soluble sulfates shall be determined in accordance with SANS 3001-AG-31 (SANS 5850-1) and shall have maximum 0,2 %
SO3 by mass; and
(vi) Tests for the presence of shell material shall be determined in accordance with SANS 3001-AG-35 (SANS 5840) and shall be maximum 5 %
by mass.
A6.1.5.4 Admixtures to concrete

No admixtures shall be used without the written permission of the Engineer. The admixtures proposed for use shall be assessed during the mix
design process and construction of the trial section.
All admixtures for concrete shall comply with the requirements of SANS 50934 (EN 934), ASTM C494 or AASHTO M194. Admixtures shall be
approved by the Engineer and be compatible with the exposure environment and cementitious binder composition. Admixtures shall have no
deleterious effects on the steel or concrete, and shall not contain any chlorides, nitrates, sulphides or sulphites, which may be detrimental.
Admixtures shall generally be supplied in liquid form and accurately dispensed by a mechanical dosing unit in a manner appropriate to the method
batching e.g. dry versus wet batching. Unless extraordinary circumstances dictate otherwise, under no circumstances shall a mixture be
dispensed directly onto the mix components. Where extraordinary circumstance does exist, other methods of feeding into the concrete mixture
shall be agreed with the Engineer. Where specified, air entraining agents may alternatively comply with the requirements of SANS 50934
(EN 934), ASTM C260 or AASHTO M154.
Where combinations of two or more admixtures are utilised, they shall be tested for compatibility. The total amount of admixtures shall not exceed
the maximum dosage recommended by the admixture producer and also shall not exceed 5 % by mass of the total cementitious binder, unless
the influence of the higher dosage of admixture on the performance and durability of the concrete is established and taken into account.
If the total quantity of liquid admixture equals or exceeds 3 litres per cubic metre of concrete, the admixture quantity shall be included in the water
content of the concrete mixture when calculating the water: cementitious binder ratio.
The alkali content (Na2O-equivalent) of all admixtures shall form part of the calculation of the alkali content of concrete in order to limit the degree
of reactivity as specified in Clause A13.4.7.2a) of Chapter 13.
Where so specifically specified, or proposed by the Contractor, any chemical or air-entraining admixtures used shall comply with the requirements
of SANS 50934 Parts 1 to 6 and shall be of an approved type and brand. In addition, admixtures shall be subject to such tests as may be
prescribed by the Engineer, carried out at an approved testing laboratory at the Contractor's expense to determine the effect of the admixture on
the concrete mix including early strength development. Admixtures containing calcium chloride shall not be used.

Admixture properties shall be uniform throughout their use in the work and stored and dispensed in liquid form.
If more than one admixture is used, the admixtures must be compatible with each other such that the desirable effects of all the admixtures used
are realized.
Admixtures shall be utilised in compliance with the manufacturer's written instructions. The instructions shall include a statement that the admixture
is compatible with the types and quantities of cementitious material intended for use.
If the use of admixtures is not specified, the dosage thereof shall be as recommended by the admixture manufacturer to achieve any enhanced
fresh or final concrete characteristics required.
A6.1.5.5 Reinforcing steel, tie-bars and dowels

a) Dimensions
The dimensions for reinforcing steel, tie-bars and dowels shall be as indicated on the drawings and Contract Documentation.
b) Reinforcing steel and tie bars
Reinforcing steel and tie-bars shall comply with the requirements of SABS 920. Tie-bars shall be deformed mild-steel bars or deformed high-yield
steel, except that any tie-bars intended to be bent and subsequently straightened shall be hot-rolled deformed mild-steel bars. The use of plate
type tie bars shall be approved by the Engineer.
c) Welded steel fabric
Welded steel fabric shall comply with the requirements of SABS 1024.
d) Dowel bars at transverse joints
Dowel bars shall be mild-steel bars having a smooth, circular section produced on a Kocksblock to ¼ DIN tolerance of the DIN 1013 specification.
Dowel bars shall be straight and free from irregularities and without any burred ends, and shall have their sliding ends sawn and bevelled. Cropping
of dowels shall not be permitted. The free or un-bonded end of the dowel shall be coated with a bond-breaking coating, as directed by the Engineer,
to prevent the concrete from adhering to it. The coating or sheath shall cover at least two-thirds of the dowel length. The bond-breaking coating
shall be an approved synthetic material applied at a thickness of 0,5 mm in accordance with the manufacturer’s recommendations. The sheath
shall be a tough polyethylene material with an average thickness of 1,0 mm ± 0,2 mm.
The use of alternative plate dowels shall be approved by the Engineer.
A6.1.5.6 Curing compound

The curing compound used shall be a white-pigmented resin-based curing compound containing no water and which complies with the
requirements of ASTM C 309, except that the water loss requirement be substituted with the efficiency-index as determined in accordance with
BS 7542. The efficiency-index shall exceed 90 % at an application rate of 0, 2 l/m2. A recent certificate not older than 3 months from an approved
testing laboratory shall be submitted, certifying that the curing compound complies with the specifications. Further testing shall be conducted at
regular intervals.
The curing compound shall be capable of hardening within 30 minutes of having been applied and of being sprayed onto a wet surface without
loss of stability, change in colour or becoming less efficacious. This characteristic shall also be confirmed by the approved testing laboratory.
A6.1.5.7 Materials for joints

a) Joint filler for expansion joints
Joint filler for expansion joints shall be manufactured from a closed-cell polyethylene and the filler strips shall be provided with tear-off cover strip.
The joint filler shall comply with the requirements of AASHTO M 153, and the particular type used shall be subject to the Engineer's approval.
Joint filler for isolation joints shall be pre-formed expansion joint filler for concrete (bituminous type) complying with ASTM D 994.
b) Silicone sealant
Unless specifically approved by the Engineer, the joint sealant shall be silicone specifically formulated for use on concrete.
(i) Sealant
The silicone sealant shall be a one-component material with low-modulus properties. The use of acid cure sealants shall not be
permitted. Silicone joint sealant must be compatible with the surface it is applied to and have properties shown in the Table A6.1.5-
1:

Table A6.1.5-1: Silicone joint sealant
Property Test method Specification
Tensile stress, 150 % elongation, 7-day cure at 25C ± ASTM D 412
0,31 MPa max
2C and from 45 % to 55 % Relative Humidity (Die C)
Flow at 25C ± 2C with 15 % slope channel A ASTM C 639 must not flow from channel
Extrusion rate through 3.18mm opening at 0.62 MPa at
ASTM C 603 min 75 g/min
Material temperature - 18C
Extrusion rate through 3.18mm opening at 0.62 MPa at
ASTM C 603 max 250 g/min
Material temperature 38C
Relative density /Specific gravity ASTM D 792
1.01 to 1.51
Method A
Durometer hardness, at -18°C, Shore A, cured 7 days at
ASTM C 661 10 to 25
25C ± 2C
Ozone and UV resistance, after 5,000 hours ASTM C 793 no chalking, cracking or bond loss
Tack-free at 25C ± 2C and 45 % to 55% Relative
ASTM C 679 less than 75 minutes
Humidity
Elongation, 7 day cure at 25C ± 2C and 45 % to 55 % ASTM D 412
500 % min.
Relative Humidity (Die C)
Set to Touch, at 25C ± 2C and 45 % to 55 % Relative
ASTM D 1640 Less than 75 minutes
Humidity
Shelf Life, from date of shipment -- 6 months min.
Bond, to concrete mortar-concrete briquettes, air cured 7 AASHTO
days at 25C ± 2C T 132 0,34 MPa min
Movement capability and adhesion, 100 % extension at -
no adhesive or cohesive failure after 5
18°C after, air cured 7 days at 25C ± 2C, and followed ASTM C 719
cycles
by 7 days in water at 25C ± 2C
Colour Grey
The Contractor shall submit a certificate, less than six months old, from an approved testing laboratory, certifying that the sealant conforms
to all the specified requirements.
The silicone sealant shall be applied by means of pumping the sealant from a storage container by means of compressed air powered
pumping equipment and applied to the joint slot by means of nozzles designed to ensure that the slot is filled with sealant as indicated on
the drawings. Application of the sealant into the joint slot by hand shall not be permitted.
(ii) Silicone sealant applied in terms of a Product Performance Guarantee System
Sealant installed in accordance with the above shall be in accordance and be assessed in terms of Part D of these specifications
(iii) Additional materials for silicone sealant
Backer rods shall comply with ASTM D 5249, Type 1. The backer rod diameter shall be at least 25 % greater than the saw cut joint
width. Backer rod material shall be expanded, cross-linked, closed-cell polyethylene foam.
The sealant shall be supported by a bond breaker backing strip, and, unless otherwise recommended by the manufacturer and
approved by the Engineer, the faces of the joint groove shall first be treated with an appropriate primer.
Supporting and priming materials shall be compatible with adjacent materials or surfaces in contact with the materials and shall be
in accordance with the recommendations by the manufacturer and subject to approval by the Engineer. Any primer used shall
form a barrier layer between the silicone and the concrete.
(iv) Materials for cleaning, repairing and resealing of existing joints and cracks
Materials used for cleaning existing joints and for repairing and sealing or resealing joints and cracks shall comply with the
provisions of the Contract Documentation. Cleaning agents shall be such that they will not stain the concrete or cause the existing
bituminous or other material to soak into the concrete.
c) Liquid sealant for joints between concrete or asphalt pavement

The liquid sealant used in joints between concrete and asphalt pavement shall be of the hot-poured type and shall comply with the requirements
of US Federal Specification SS-S-1401, or any other type as may be approved by the Engineer.

A6.1.6.1 General
The Contractor shall ensure the equipment and tools intended for use shall meet the following:
- The capability for handling the proposed materials and performing all parts of the work within the specifications.
- Production rates of such capacity that the paver operates continuously and at a constant rate of production, with starting and stopping
reduced to a minimum.
Before any concrete may be cast, the Engineer shall approve the concrete source, batching methodology, all assembled side-forms, guide wires
and/or rails and the paving train configuration. For this purpose, the Engineer shall be given sufficient notice and opportunity. Approval by the
Engineer shall not relieve the Contractor of any of his obligations to construct the concrete pavement in accordance with the specified quality,
dimensions and relevant tolerances.

A6.1.6.2 Concrete batching plant
The intended concrete batching plant or supply source shall be of sufficient capacity to ensure that, as far as practically possible, there is an
uninterrupted supply of concrete during paving operations. Concrete may be produced in either of the following manner:
- Batching on site by an approved and dedicated plant
- Sourced from a ready-mix commercial supplier
Where concrete is supplied by a commercial source outside the direct control of the Engineer, the concrete supplier shall ensure compliance with
the requirements of SANS 50206 (SANS 878). The Contractor shall have full responsibility to implement process control testing in accordance
with the specifications. Commercial concrete suppliers shall ensure that the plant, measuring, mixing, transporting and associated processes are
audited by a recognised independent body in accordance with the following requirements for commercially sourced concrete:
(i) ISO 9002 (Standardisation);

(ii) ISO 14001 (Environment);
(iii) ISO 39001 (Road transport safety management);
(iv) OHSAS 18001 (Legal compliance);
(v) SANS 50206 (SANS 878), ISO 22965-2 or ISO 9001 (Quality management system for concrete production).
A6.1.6.3 Side-form paving

a) Side forms
Before any side-forms may be ordered or brought onto the site, particulars regarding the side-forms shall have been approved by the Engineer.
Side-forms and rails shall be so designed, manufactured, set and supported that the completed concrete pavement will comply with all the
requirements of Clause A6.1.8. When assessed with a 3,0 m straight-edge, the top edge of the form shall not deviate by more than 3,0 mm at
any place, and the sides by more not than 6,0 mm. The sides shall not deviate by more than 3,0 mm from the vertical. The maximum height that
the side-forms may be raised in order to achieve the specified layer thickness shall be 15 mm.
The wheels of spreading, compaction, finishing machines and frame-mounted covers shall not run directly on the top surface on the side-forms but
on rails rigidly attached to the forms, unless the forms are specially made to double as rails.
There shall be sufficient length of side forms available and provided so that it is not necessary to remove them less than 12 hours after placing the
concrete. All forms shall be thoroughly cleaned and treated with an approved releasing agent prior to reuse.
b) Paving train
The equipment shall be of such dimensions and arrangement so as to cover the full width of the pavement strip being placed with the minimum
amount of hand work required. The paving train shall essentially consist of the following items of equipment:
(i) Hopper/spreader
A purpose made spreader/hopper running on rails and capable of spreading the delivered concrete laterally and evenly to a uniform
un-compacted density over the entire surface of the slab without segregation.
(ii) Consolidation/compaction equipment
Consolidation of the concrete shall be executed by appropriate mechanical surface vibrators, internal vibrators and tampers. The
power supply to the vibrators shall cut out automatically as soon as the compaction equipment stops moving. Suitable internal
vibrators shall be used against the side- forms and at joint assemblies to ensure full compaction throughout the pavement layer.
For the surface vibrators, a frequency of not less than 3,500 impulses per minute shall be utilised. For internal type vibrators, a
frequency of not less than 5,000 impulses per minute for tube vibrators and not less than 7,000 impulses per minute for spud
vibrators shall be utilised.
Where spud-type internal vibrators adjacent to forms are utilised, either hand-operated or attached to spreaders or finishing
machines, a minimum frequency of 3,500 impulses per minute shall be used. The Contractor shall measure and record the
frequency of internal vibrators in plastic concrete and submit data to the Engineer. Where spud vibrators are mounted such that
the free tip trails, they shall be spaced at a maximum interval of 750 mm.
(iii) Initial finisher
The surface of the concrete shall be finished smooth and true to grade and level by means of an initial finishing machine equipped
with a transverse or oblique oscillating beam. The machine shall be capable of being readily adjusted for changes in slab thickness,
cross-fall, height and tilt.
(iv) Final finisher
The final finish of the surface shall be carried out by a machine which incorporates twin oblique oscillating finishing beams. The
beams shall be readily adjustable for both height and tilt. The leading beam shall be vibrated. The beam shall be supported on a
carriage with two wheels on either side at least 3,5 m apart in the longitudinal direction. The oscillating beams shall be of
rectangular section, spanning the full width of the slab and each weighing not less than 170 kg/m.
(v) Frame mounted canopy.
The Contractor shall provide a frame mounted canopy to protect the plastic finished concrete from any damage as a result of rain
or other unfavourable weather conditions. The length of the protective canopy shall be appropriate to the expected production
rates.
A6.1.6.4 Slip-form paving

a) Slip-form paver
The Contractor shall provide a slip-form paver that is self-propelled and equipped to spread, strike-off, consolidate, screed, and float-finish the
freshly placed concrete in one complete pass of the equipment in such a manner that a minimum amount of hand-finishing will be necessary to
provide a dense and homogeneous pavement. The equipment shall be of such dimensions and arrangement so as to cover the full width of the
pavement strip being placed.

The paving equipment shall be adjustable as to crown and super elevation and capable of shaping and consolidating the concrete into a dense
and stable mass to the required cross-section. Any crown adjustments shall be readily controllable for accuracy in crown transitions.
The paver shall operate on tracks having sufficient contact area to prevent track slippage under load. Ensure that the length of ground contact per
track and the arrangement of tracks are adequate to meet the straightedge and other riding-quality requirements specified. Spreading shall be
accomplished by either:
• oscillating screeds,
• an extrusion device, or
• a combination of both.
If necessary, the slip-form paver shall be equipped with traveling side forms of sufficient dimension, strength and of proper shape in order to
support the concrete laterally for a sufficient length of time during placing and finishing.
b) Electronic control systems
Where a slip-form paver is used, the alignment levels for placing the concrete, shall be controlled automatically from guide wires by sensors
attached at the four corners of the slip-form paving machine. The alignment and level of ancillary machines for finishing, texturing and curing shall
be automatically controlled relative to the guide wires and to the surface and edges of the slab. Guide wires shall be so designed, manufactured
and fixed that the paver will be capable of producing a completed slab which will comply with the requirements of Clause A6.1.8.
Other control methods, such as a string-less paving system incorporating appropriate 3D/GPS technology may be permitted after assessment
and approval by the Engineer.
A6.1.6.5 Burlap drag equipment

Unless otherwise authorised by the Engineer, the burlap drag shall be attached to the front of the texturing machine or to an additional machine
which spans the full width of the concrete pavement and is placed in such a way that the full width of the concrete pavement is covered in one
operation and, when not in use, the entire drag can be lifted clear off the pavement.
The dimensions of the burlap drag shall be such that at least 1,0 m of the material is in contact with the surface of the concrete pavement measured
in the direction in which the drag is being moved. The burlap drag shall consist of at least two layers of approximately 340 g/m 2 burlap with the
bottom layer at least 150 mm longer than the top layer at the dragging end. However, if the required texture is not obtained, then at the discretion
of the Engineer, the number of layers may be increased to four. The transverse threads of the trailing 150 mm to 300 mm of the burlap drag shall
be removed.
A6.1.6.6 Texture grooving equipment

Unless otherwise approved, the required tine texturing shall be effected by means of a machine which spans the full width of the concrete
pavement, and which is guided in regard to both level and direction by the rails in the case of side form construction, or by the paver guide wires
in the case of slip form construction.
The grooving tines shall be made from individual flat spring steel approximately 0,6 mm in thickness and 3,0 mm in width, 125 mm in length and
spaced at between 12 mm and 25 mm in an approved random pattern. The Engineer may, however, require a different random pattern or equal
spacing of the tines during the course of the work, and provision shall be made to supply different sets of combs as required. No additional
payment will be made for the first two changes in the spacing of the tines. The comb frame for applying the texturing shall be at least 2,0 m wide.
It must also be possible to adjust the combs to a lower position in order to compensate for wear.
Where so specified in the Contract Documentation, the fresh concrete shall be broom textured utilising appropriate equipment just prior to applying
the curing compound.
A6.1.6.7 Applicator for curing compound membrane

The Contractor shall provide equipment for applying curing compound that is self-propelled and capable of uniformly applying the curing compound
at the specified rate. The equipment shall be capable of continuously stirring the curing compound by effective mechanical means to keep the
pigmentation in suspension. The curing compound shall be thoroughly atomized during the spraying operation so that the finished surface
appearance of the fresh concrete will not be marred. The entire surface of the pavement shall be covered by a single pass of the machine and,
with slip-form type paving, shall also include the vertical exposed faces. Spray nozzles shall be equipped with appropriate wind guards to ensure
uniform application.
Hand operated power-spray equipment may be used to apply curing compound to areas where it is impracticable to operate the self-propelled
equipment.
A6.1.6.8 Equipment for paving small or narrow areas

For minor roads, variable width areas, other than mainline, ramps, and shoulders, the Engineer will not require the full slipform paver as specified
for the standard run of paving. In such instances the Contractor shall utilise appropriate hand equipment and construction methods as prescribed
in Part B of this Chapter in order to achieve the desired final product as specified. The Contractor shall provide a comprehensive method statement
and quality plan to the Engineer for approval prior to commencing with any such work.

A6.1.7.1 Preparing the underlying layers
a) General
The underlying layers shall be constructed in accordance with the relevant standard specifications, and any additional relevant Contract
Documentation as may be prescribed, up to the level of the underside of the concrete slab. The surface of the layer directly below the concrete
should not be smooth, loose or show signs of lamination.

The Contractor shall note the provisions of Chapter 1 in regard to the use of construction tolerances for successive pavement layers and shall
make provision in his prices for any additional concrete which may be necessary in respect of irregularities in the layer underlying the concrete
pavement.
b) Applying the prime or bond coat
Unless otherwise specified in the Contract Documentation, a bituminous prime coat shall be applied to the completed cementitious stabilised
subbase layer in accordance with the requirements of Chapter 8: Pre-treatment and Repair of existing Layers. Where the underlying subbase
layer consists of asphalt, a bituminous bond coat shall be applied in accordance with the relevant requirements of Chapter 9: Asphalt Layers. The
nominal application of 0,3 l/m² net bitumen shall be applicable in each instance. Before any pavement concrete is placed, the prime or bond coat
shall be cured and shall be checked. Any areas having deficient or poor application, or where damaged, shall be repaired as directed by the
Engineer. The coated surface shall then be thoroughly cleaned and shall be dry before any reinforcing steel, tie bars, dowels or concrete may be
placed.
c) Wetting the subbase
The subbase shall be kept continuously wet for a period of at least one hour before the concrete is placed. Immediately before the concrete is
placed, the excess water shall be broomed off the road ahead of the paver so as to ensure that the subbase will still be damp when the concrete
is placed. No puddles of water or deleterious matter shall be left on the road.
A6.1.7.2 Batching and mixing of concrete

a) General
Concrete may be batched at a dedicated mixing plant on site, or supplied by a commercial ready mix facility. In either instance the concrete shall
conform to the requirements as listed in Clause A6.1.6.2 Concrete Batching Plants. All constituent materials shall be stored and handled so that
their properties do not change, for example due to climate conditions, intermingling or contamination, and that their conformity with the respective
standard is maintained.
b) Cement and supplementary cementitious materials
Cement and supplementary cementitious materials stored on the site shall be kept separately under cover which provides adequate protection
against moisture and other factors which may promote deterioration of the cement or supplementary cementitious material.
Cement and supplementary cementitious material may only be used if stored and maintained at a temperature less than 45°C. In hot weather
concreting conditions, the cement and supplementary cementitious material storage facilities shall be painted with white high solar reflectance
paint and insulated to reduce any temperature rise in the stored cement or supplementary cementitious material.
Cement or supplementary cementitious material supplied in bags shall be closely and neatly stacked, separately to a height not exceeding 12 bags
and arranged so that they will not be in contact with the ground, the floor or the walls, and can be used in the order in which they were delivered
to the site.
Cement or supplementary cementitious material supplied in bulk shall be stored separately in waterproof containers so designed as to prevent
any dead spots from forming, and the cement or supplementary cementitious material drawn for use shall be measured by mass.
Cement shall not be kept in storage for longer than 8 weeks without the Engineer's permission, and different brands or types of the same brand
of cement or supplementary cementitious material shall be stored separately.
c) Aggregates
Aggregates of different nominal sizes, sources or types shall be stored separately. Intermixing of different materials and contamination by foreign
matter shall be avoided. Aggregates exposed to a chloride (XS) environment (refer Table A13.4.7-2 of Chapter 13) shall be covered to protect
them from salt contamination. Sufficient quantity of fine aggregate shall be stockpiled on site and handled in a manner that ensures the thorough
mixing of the various deliveries in order to achieve a stable fineness modulus within the specified limits.
In hot weather concreting conditions, both the coarse- and fine-aggregate stockpiles shall be shaded from the sun. When the ambient temperature
reaches and at all times when it exceeds 30°C, only the coarse aggregate shall be sprayed with water to assist cooling by evaporation. Water
shall be delivered by means of an approved water droplet sprayer system. The Contractor shall ensure adequate drainage of the aggregate
stockpile area.
Where concrete is batched on site, the aggregates shall be stored in bins with a minimum 150 mm thick concrete floor constructed below the
aggregate stockpile to prevent contamination during the storage and handling the aggregate. The floor slab shall be appropriately sloped to
facilitate drainage of the stockpile area. A 3,0 m wide concrete apron slab shall be constructed around the entrance and outer edge of the
aggregate stockpile area and sloped for drainage away from the main stockpile area. The aggregates shall be tipped on the concrete apron slab
to prevent contamination during the process of tipping and hoisting the aggregate.
d) Water
In hot weather concreting conditions, the sides and tops of water tanks for mixing water, including pipework leading to and from tanks, shall be
insulated.
e) Storage capacity
The storage capacity provided and the quantity of material stored, whether cement, supplementary cementitious materials, aggregates,
admixture or water, shall be sufficient to ensure that no interruptions to the progress of the work will be occasioned by any lack of materials.
f) Deteriorated material
Deteriorated or contaminated or otherwise damaged non-conforming material shall not be used in concrete. Such material shall be removed
from the site without delay.

g) Proportioning the components
(i) Cementitious binder
Where cementitious binder is supplied in standard bags, the bags shall be assumed to contain 50 kg for batching purposes.
Cementitious binder taken from bulk storage containers and from partly used bags shall be batched by mass, accurate to within
2 % of the required mass.
(ii) Water
The mixing water for each batch shall be measured, either by mass or by volume, accurate to within 2 % of the required quantity.
The quantity of water added to the mix shall be adjusted to make allowance for any moisture in the aggregates.
(iii) Aggregates
All aggregates for concrete shall be measured separately by mass, except as otherwise provided in this Clause, accurate to
within 3 % of the required quantity.
(iv) Admixture
Admixtures shall generally be supplied in liquid form and accurately dispensed by a mechanical dosing unit, into solution with the
mixing water, except where the admixture cannot be dispersed homogenously into the mixing water. Unless extraordinary
circumstances dictate otherwise, under no circumstances shall admixtures be dispensed on to dry mix components. Where such
extraordinary circumstances do exist, in such cases, other methods of feeding into the concrete mixture shall be agreed with the
Engineer.
All admixtures shall be dispensed in quantities accurate to within 2 % by mass of the desired quantity. The mechanical dosing
unit shall be checked daily for accuracy using a nominal dispensing volume, typically 2 litres, or as recommended by the dosing
unit manufacturer or admixture supplier. At least once a week, the dosing unit shall be checked for accuracy using the full
dispensing volume suited to the concrete mixing procedures employed on site, typically for 6 cubic metre concrete batch mixed
by a standard mixing truck and proportionally for other standard batch volumes.
h) Mixing the concrete

(i) General
Mixing the material for concrete shall be conducted by an experienced operator. Unless otherwise authorised, mixing shall be
carried out in a mechanical mass batch-mixer of an approved type which will be capable of producing a uniform distribution of
ingredients throughout the batch.
(ii) Charging the mixer

The sequence of charging the ingredients shall be subject to approval by the Engineer, and, unless otherwise instructed, the
same sequence of charging the ingredients shall be maintained. Fibres, pigments and colouring agents shall be added to the
mix in a manner that ensures that they are uniformly dispersed in the mix.
The volume of the mixed material by batch shall not exceed the volume recommended by the manufacturer of the mixer.
(iii) Mixing and discharging

The period of mixing shall be measured from the time when all the materials are in the drum until the commencement of
discharge.
The mixing period for the materials shall be at least 90 seconds and may be reduced only if the Engineer is satisfied that the
reduced mixing time will produce concrete with the same strength and uniformity as concrete mixed for minimum 90 seconds.
The reduced mixing time, however, shall be not less than 50 seconds or the manufacturer's recommended mixing time,
whichever is the longer. A suitable timing device shall be attached to the mixer to ensure that the minimum mixing time for the
materials has been complied with.
The first batch to be run when starting with a clean mixer, shall contain only 75 % of the required quantity of coarse aggregate
to make provision for coating the mixer drum. Refer Clause A13.4.7.12g) of Chapter 13 for a similar provision for richer concrete
mix placed at horizontal construction joints.
Discharge shall be so carried out that no segregation of the materials will occur in the mix. The mixer shall be emptied completely
before it is recharged with fresh materials.
(iv) Maintaining and cleaning the mixer

If the mixer has stopped running for a period in excess of 30 minutes, it shall be thoroughly cleaned out with particular attention
being given to the removal of any build-up of materials in the drum, in the loader, and around the blades or paddles.
Before any concrete is mixed, the inner surfaces of the mixer shall be cleaned and all hardened concrete shall be removed.
Worn or bent blades and paddles shall be replaced.
i) Transporting the concrete

Concrete shall be so transported to its final position that segregation or loss of any of the ingredients, or contamination, will be prevented, and
that the mix is of the required workability at the point and time of placing.
The Contractor will be permitted to use appropriate truck mixers which agitate previously mixed concrete in transit.

The fresh concrete shall be protected against rain, heat, direct sunlight and/or evaporation by means of covers on all open vehicles. No additional
water may be added in transit or where delivered.
The time lapse from the moment when the cement and aggregate are intermingled up to the time of placing and compacting the concrete shall
not exceed 60 minutes when concrete is transported in truck agitators, and shall not exceed 45 minutes in mild weather, or 30 minutes when the
concrete temperature is 30C or higher, when transported in ordinary trucks.
A6.1.7.3 Placing, Compacting and Finishing Concrete

a) General requirements for both side-form and slip-form paving
(i) Maintaining continuity during placing

The Contractor shall make adequate advance arrangements for preventing delay in delivering and placing the concrete. An interval
of more than thirty minutes between the placing of any two consecutive batches or loads of concrete shall constitute sufficient
reason for the Engineer to have the paving operations stopped, and the Contractor shall, then at his own expense, make a
construction joint in the concrete already placed, at the location and of the type directed by the Engineer. Paving operations shall
be continuous, and the rate of paving shall be adjusted to suit the rate of delivery of the concrete.
(ii) Time for placing and compacting
The placing, compacting and finishing of the concrete shall be carried out as quickly as possible, and the operations shall be so
arranged that, in any transverse section of the pavement, the concrete shall be fully compacted and finished within 2,5 hours of
having been mixed. This time shall be reduced by half an hour for every 5C by which the concrete temperature is above 20C at
the time of placing, unless otherwise permitted by the Engineer.
Unless adequate lighting facilities, approved by the Engineer, are provided beforehand by the Contractor, the placing of concrete
pavement shall cease in good time so that the finishing operation can still be completed during daylight hours.
(iii) Compacting
The concrete shall be fully compacted by means of approved equipment and shall be free from honeycombing and planes of
weakness. The average amount of air voids in concrete cores shall not exceed 1,5% when measured by the visual assessment
method described in SANS 5865 (SANS 3001-CO3-5).
Over-vibration resulting in segregation, surface laitance, or leakage (or any combination of these) shall not be acceptable.
No paving in the downhill direction will be allowed if tearing of the concrete occurs. The Contractor shall take the necessary
measures to the satisfaction of the Engineer to prevent tearing of the concrete, for example by carrying out the paving in the uphill
direction.
(iv) Width of placing
The width of concrete pavement strip to be placed in a single uninterrupted operation shall be as agreed with the Engineer so that
longitudinal construction joints do not, as far as practical, fall within the wheel paths of the relevant lanes.
(v) Placing of tie bars
Tie-bars shall be placed as indicated on the drawings and shall be placed at right angles to joints. Tie-bars shall be free from
paint, grease or other matter which may affect bonding with the concrete.
At longitudinal construction joints the one half of each tie-bar shall be supported on the subbase by means of suitable stools, while
the other half shall project into the adjacent lane through the side forms. The arrangement and spacing and fixing of the tie bars and
stools shall be such that they shall be supported in position without deflection or displacement when a dead load of 100 kg is applied
or during placement and compaction of the concrete. Mild steel tie-bars at longitudinal joints may be bent parallel to the edge of the
first lane constructed and later on straightened into its final position before the concrete of the adjacent lane is placed. The method
of fixing and supporting the tie-bars shall be approved by the Engineer. Where tie-bars are bent and later straightened due to
traffic accommodation constraints, any damage to the concrete shall be made good by the Contractor.
At longitudinal weakened-plane hinge joints the bars shall be firmly supported in position by steel supporting devices fixed to the
subbase. If the paver or other paving equipment is equipped with a device for placing tie-bars into the plastic concrete, such device
may be used only after it has been demonstrated that the tie-bars will be located in their correct positions after the slab has been
compacted and finished.
(vi) Placing of dowel bars
Dowel bars shall be installed at locations as indicated on the drawings. Dowels shall be fixed rigidly both in horizontal and vertical
alignment parallel to the centre line of the road and the surface of the slab, by robust supporting frames or cradles which do not project
within 150 mm of the joint and are left permanently in place. The frames shall be fixed to the subbase so that they will be stable and
remain undisturbed during paving operations. The free end of the dowel shall not be tack-welded to the frame but shall be held in
position by soft binding wire. Dowels may be mechanically inserted, in which case no frames will be required for securing the dowels,
provided that conclusive evidence is submitted that the proposed method is an accepted method and has already been used
successfully. Dowel alignment shall be accurate to within the tolerance given in Clause A6.1.8.
(vii) Placing of continuous reinforcing steel in continuously reinforced concrete pavement
The continuous steel reinforcement shall be free from dirt, oil, paint, grease or other organic materials, which may adversely affect or
reduce the bond with the concrete. Loose surface rust caused by lengthy storage shall be removed.
The arrangement and spacing and fixing of the chairs or stools shall be such that the reinforcing shall be supported in position without
deflection or displacement when a dead load of 100 kg is applied or during placement and compaction of the concrete. The chairs
shall be so supported as to prevent them overturning on the subbase when the paving train passes over them.
(viii) Placing of steel mesh in jointed concrete pavement
The reinforcing concrete welded mesh detail shall be as indicated on the drawings. The steel shall be free from dirt, oil, paint, grease
or other organic materials which may adversely affect or reduce the bond with the concrete. Loose surface rust caused by lengthy

storage shall be removed. The steel mesh sheets shall be handled with care so that they remain reasonably flat and free from
distortions. The sheets shall be free from kinks or bends that will prevent them from being properly assembled and installed. The
arrangement and spacing and fixing of the chairs or stools shall be such that the reinforcing shall be supported in position without
deflection or displacement during placement and compaction of the concrete. The reinforcement shall not straddle intended joints.
(ix) Burlap drag finish
This texture shall be obtained by first applying a burlap-drag, as specified in Clause A6.1.6.5, as a finish to the concrete surface.
The first pass of the burlap drag shall be made as soon as construction operations permit and before the wet sheen has
disappeared from the surface. Burlap dragging shall be repeated until a gritty and uniform texture having the required finish and
depth of texture has been obtained.
Every morning the burlap drag shall be wetted and shall kept moist throughout the day. At the end of each day's production the
burlap mats shall be cleaned or discarded and replaced with new burlap if cleaning is not possible.
(x) Surface texturing
After completing the burlap finish described above, the pavement surface shall be further textured by means of a broom finish or
grooving comb as stated in the Contract Documentation. The grooving comb shall be as specified Clause A6.1.6.6. The direction
of the texturing shall be at right angles to the longitudinal axis of the pavement. Surface texturing shall extend over the full width
of the pavement.
The surface texture shall be applied and completed before the concrete is so hard that the surface will be torn and coarse aggregate
unduly loosened during texturing. When measured with a suitable depth gauge, the grooves shall be not less than 2,0 mm and not
more than 4,0 mm in depth.
After the concrete has hardened, all loose particles generated by the cutting of the grooves shall be broomed off the surface with
stiff hand brooms or mechanically-operated rotary brooms.
The Engineer may permit the use of texturing equipment other than the grooving comb, provided that it produces a texture similar
to that produced by the metal tines.
Texturing the surface with hand-held brooms or combs shall be allowed only where the pavement is so small or irregular, or the site is
so restricted as to make the use of the texturing machine impracticable, or in cases of mechanical breakdown of the texturing machine,
in which case it may be used for the required texturing of concrete already placed. The brush or comb to be used then shall be of the
same type and width used in the machine. In order to ensure straight grooves the comb shall be operated against a straight-edge
placed at right angles to the pavement centre line. The same requirements regarding groove dimensions or texture depth as for
machine-texturing shall apply.
(xi) Curing
Immediately after the completion of texturing, a white-pigmented curing compound complying with the requirements of Clause
A6.1.5.6, and in accordance with the direction of the manufacturer, shall be applied.
In the case of slip-form paving, the exposed surfaces, including the sides of the slab, shall be treated immediately after the required
texturing of the surface has been effected. In the case of side-form paving the surface shall be treated immediately after the
texturing has been completed and the sides of the panels after the side formwork has been removed
The curing compound shall be sprayed onto the surface at a rate of 0,35 l/m 2 or as directed by the Engineer by means of a
mechanical distributor capable of producing a fine fog-type of spray which will not damage the surface of the concrete. The curing
compound shall be applied in two layers with the distributor moving in opposite directions for the two applications. Coverage shall
be uniform over the entire surface and the rate of application of the curing compound shall be carefully controlled.
During spraying operations the curing compound shall be continuously stirred mechanically to keep the pigmentation in
suspension. The spray nozzles shall be adequately protected against wind.
After shutting off the spray nozzles, no dripping of curing compound on the concrete surface may occur. If necessary, the
Contractor shall provide drip pans suspended below the nozzles to prevent dripping of the curing compound onto the pavement.
The curing membrane shall be maintained intact for at least seven days after the concrete has been placed. Any damage to the
curing membrane shall be repaired by hand-spraying the affected areas.
Areas inaccessible to the mechanical distributor such as odd shaped areas, those with varying widths or shapes or the sides of
the slabs after removal of the form work, shall be sprayed with curing compound by means of approved hand spraying equipment,
at the specified rate of application.
b) Side-form paving
(i) Side form set up

The side forms shall be accurately set to line and grade and in such a manner that they rest firmly, throughout their entire length,
upon the subgrade surface. The forms shall be connected neatly and tightly, and braced in order to resist the pressure of the
equipment operating on the forms. The Contractor shall obtain the Engineer’s approval of the alignment and grade of all forms
immediately prior to the placing of concrete.
Any voids between the established grade of the form line and the layer on which it is supported shall be caulked with a stiff mortar
consisting of one part of rapid-hardening cement and 3 parts of sand by volume and finished vertically on the inside. The mortar
shall have hardened sufficiently before any concrete may be cast against it. The rails, side-forms and running surface shall be
kept clean in front of the wheels of all paving equipment.
As an exception, when placing forms on a cement-treated or asphalt subbase layer, the Contractor may use wedging, provided
that the wedging system used adequately supports the forms without causing detrimental deflection under the weight of the paving
equipment.
A sufficient number of forms shall be available on site at all times to ensure that at least 150 m of formwork can be accurately set
and maintained true to line and grade in advance of the point where concrete is being placed. Sufficient forms shall also be provided

so that it is not necessary to remove them less than 12 hours after placing the concrete. All forms shall be thoroughly cleaned and
treated with an approved releasing agent prior to reuse.
(ii) Placing and spreading the concrete
The concrete shall be spread uniformly by means of a purpose-made mechanical hopper spreader running on rails and capable
of spreading the concrete uniformly to a specified level and to a uniform un-compacted density over the entire surface of the slab.
The machines shall be capable of being rapidly adjusted for changes in slab thickness or cross-fall.
(iii) Compaction
The concrete shall be fully compacted by vibration or by a combination of mechanical surface vibration, internal vibration and
tamping. The power supply to the vibrators shall cut out automatically as soon as the compaction equipment stops moving. Suitable
internal vibrators shall be used against the side- forms and at joint assemblies to ensure compaction throughout the pavement
layer.
(iv) Final finishing
The surface of the concrete shall be finished smooth and true to grade and level by means of an initial finishing machine equipped
with a transverse or oblique oscillating beam. The final finish of the surface of the slab shall be carried out by a machine which
incorporates twin oblique oscillating finishing beams. The beams in the case of both machines shall be readily adjustable for both
height and tilt, and the leading beam shall be vibrated. The beam shall be supported on a carriage with two wheels on either side,
at least 3,5 m apart in the longitudinal direction. The oscillating beams shall be of rectangular section, spanning the full width of
the slab and each weighing not less than 170 kg/m.
Hand-finishing of the concrete surface shall be reduced to the absolute minimum and shall be used only to correct minor
imperfections and marks on the surface. Before the concrete starts setting, all pavement edges, and the edges of joints, shall be
rounded off to the prescribed radius.
After finishing, the Contractor shall test the concrete surface with a straight-edge of at least 3,0 m in length. Irregularities indicated
by the straight-edge shall be removed with a long-handled hand-operated scraping straight-edge of at least 3,0 m length. A
gangplank shall be used when walking on the concrete.
Before the concrete starts setting, all pavement edges, and the edges of joints, shall be rounded off to the required radius.
(v) Constructing the pavement in more than one contiguous strip
Where concrete is placed adjacent to an existing pavement, that part of the paving equipment running on the existing pavement
shall have flanged wheels on flat-bottom section rails weighing not less than 15 kg/m or by replacing the flanged wheels on that
side of the machines by smooth flangeless wheels. Before the paving operation commences the surface regularity of the existing
pavement shall comply with Clause A6.1.8 and be thoroughly cleaned and brushed to remove all extraneous materials. The
wheels shall run at a distance of not less than 300 mm from the edge of the pavement to prevent the pavement edge from spalling
or cracking.
No equipment or construction traffic shall be permitted on the completed pavement until the concrete is strong enough to prevent
damage from occurring, but in any case not earlier than 14 days after the construction of the slab.
Where visible cracks occur or any other damage is done to the pavement, further work involving the paver shall be suspended
immediately. The Contractor shall repair all damage at his own cost.
(vi) Removal of side forms
Side-forms shall not be removed before the concrete has hardened sufficiently to prevent damage being done to the sides and
loosening of tie-bars or dowels, if any, and not earlier than 12 hours after the completion of the construction of the slab. The side-
forms shall also be removed timeously to permit the sawing of transverse joints up to the edges of the concrete slab. Projecting
tie-bars and/or the concrete shall not be damaged during removal of the side-forms.
c) Slip-form paving
(i) Placing and spreading

The paver shall include a spreader box or auger capable of distributing the delivered concrete evenly to the specified level and to a
uniform un-compacted density over the entire surface of the slab. The machines shall be capable of being rapidly adjusted for
changes in slab thickness or cross-fall requirements.
(ii) Compaction
The slip-form paver shall compact the concrete over the full paved width by means of internal vibration only, or by a combination of
internal and surface vibration. The vibration shall be variable with a maximum energy output of at least 2,5 kN per metre width of
slab per 300 mm depth for a laying speed of up to 1,5 m per minute or pro rata for higher speeds.
(iii) Finishing
The level and grades of the surface shall be automatically controlled within the prescribed tolerances by means of a sensing device
running on guide wires or a suitable 3D string-less system as approved. The consistency of the concrete shall be so controlled that
the edge slump will not exceed the tolerance specified in Clause A6.1.8. If approved by the Engineer, metal side-forms of sufficient
thickness and stability may be used to maintain the proper shape and line.
After the concrete layer has been completed by the finishing devices incorporated in the slip-form paving equipment, the surface of
the concrete shall be checked by means of a straight-edge of not less than 3,0 m in length. High spots indicated by the straight-
edge shall be removed by hand floats.
After the final finishing and texturing of the concrete, but before curing, the pavement edges shall be rounded manually to the
prescribed radius.

(iv) Constructing the concrete pavement in more than one contiguous strip
Except for the wheels, which shall, in the case of slip-form pavers, be replaced with rubber cushioned crawler tracks, the
provisions of Clause A6.1.8 shall apply when concrete is being placed in more than one contiguous strip.
(v) Track support
The Contractor shall at his own cost ensure that adequate track support is provided to suit the needs of the slip-form paver, either
by extending the upper pavement layers or by providing alternative support layers.
d) Placing, compacting and finishing with hand equipment
Where the slabs are too small or irregular, or the site is so restricted as to render the use of the methods described in Part A of this Chapter
impracticable, concrete shall be placed, compacted and finished in accordance with Part B of this Chapter.
A6.1.7.4 Joint forming

a) Construction joints
Construction joints shall be made only in accordance with the details and in the positions shown on the drawings or determined by the Engineer.
Where the pavement is constructed in more than one strip, longitudinal construction joints shall be constructed, and where edge slump in excess
of 6,0 mm occurs with slip-form paving, the sides of the pavement shall be supported by an approved method.
Transverse construction joints shall be formed at the end of a day's work or where necessary on account of any unavoidable suspension of work.
The upper edges of the pavement shall be rounded off or chamfered at a construction joint as shown on the drawings. Where sealing of the
construction joint is required, the groove may be sawn only after seven days' curing of the concrete.
b) Weakened-plain longitudinal hinge joints
Hinge joints shall be sawn where the pavement is constructed in widths of two or more lanes at a time. Sawing shall be done at an appropriate
time, dependant on the cement type used and ambient temperatures to prevent longitudinal cracking from occurring, but not later than 24 hours
after concrete placing.
The widths and depths of the groove and the joint filler shall be in accordance with the drawings. The width tolerances for hinge joints shall be as
prescribed out in Clause A6.1.8.
Deformed steel tie bars shall be installed where indicated on the drawings.
c) Weakened-plain transverse contraction joints
Transverse contraction joints shall initially be sawn as specified in Clause A6.1.7.4e) and shall not exceed 3,0 mm in width. The grooves shall be
sawn to the depth shown on the drawings. The exact time and sequence of sawing shall be determined by the Contractor, bearing in mind the
risk of excessive ravelling and spalling with early sawing, and the risk of cracking with delayed sawing, but shall not later than 24 hours after the
concrete has been placed.
When the pavement is constructed in more than one strip, the transverse joints opposite those which have opened in the adjacent pavement shall
be sawn within the first 24 hours. The Contractor may initially omit up to two consecutive planned contraction joints and shall saw such joints
within 48 hours of the concrete having been placed, but before uncontrolled cracking takes place.
All transverse joints shall initially be sawn to the full depth as indicated, and not more than 3,0 mm wide. In sealed joints the top portion of the
groove shall be reamed out to the specified final width and depth not sooner than 7 days after the initial sawing.
Joints shall be sealed in accordance with the details shown on the drawings or as specified in the Contract Documentation.
d) Expansion joints
Expansion joints shall be constructed in accordance with the details shown on the drawings. The joint filler shall comply with the requirements of
Clause A6.1 5.7 and holes for the dowels shall be accurately drilled. The filler for each joint shall be supplied in a single piece for the full depth
and width required for the joint unless otherwise authorised by the Engineer. Where the use of more than one piece is authorised for a joint, the
abutting ends shall be securely fastened, and held accurately in shape, by stapling or by another suitable method acceptable to the Engineer.
The joint filler together with the sealing groove shall completely separate adjacent slabs. Any loose-fitting dowel bars and any spaces between
the subbase and the filler shall be caulked with joint-filler material after the joint has been assembled.
If expansion joints incorporate dowels, the dowels shall be encased at one end in a close-fitting cap. The cap shall be placed on the free half of
each dowel which half shall be coated as late as possible before concreting, with a bond-breaking coating or sleeve which complies with the
requirements of Clause A6.1.5.5d).
The sealing groove in the upper portion of the expansion joints shall be sealed with a preformed neoprene compression seal or any other
appropriate sealant prescribed or approved.
e) Sawing of joints
The Contractor shall be responsible for determining the optimum time for the sawing of joints. This shall depend on the strength gain characteristics
of the cementitious products incorporated in the concrete mix, the hardness of the aggregate and weather conditions at the time of placing. The
Contractor shall use the type of blade and equipment best suited to the hardness of the concrete, type of aggregate and the site conditions in
order to prevent uncontrolled cracking and any spalling adjacent to the joint being sawn.
Sufficient standby power saws shall be held available by the Contractor, ready for use, at all times when concrete is being placed in the pavement.
Immediately after sawing, the joint grooves shall be washed out with a jet of clean water to remove all fine material which shall be appropriately
disposed of at an approved site. The joints shall then be sealed temporarily by means of an approved material, flush with the permanent surface.
No traffic of any kind shall be allowed on the pavement until all the joints have been permanently sealed.

f) Opening to traffic
No vehicle with an axle load exceeding 20 kN shall be permitted to travel over the completed surface within 14 days after it has been completed,
or such longer period as may be directed by the Engineer.
A6.1.7.5 Joint sealing

Joints shall be permanently sealed before the pavement is opened to any traffic.
a) Silicone sealant
(i) Materials
The silicone sealant and appurtenant materials shall be as specified in Clause A6.1.5.7b). The dimensions and positions of the sealant
and appurtenant materials shall be as shown on the drawings, as specified in the Contract Documentation, or as approved by the
Engineer.
(ii) Installation
Just prior to sealing, the joint grooves shall be reamed to their prescribed final dimensions and shall then be cleaned by means of a
high pressure jet of water over the full depth of the joints to remove all fine matter and to produce dust-free joint grooves. Immediately
before the supporting material is supplied, the grooves shall be dried by means of oil-free compressed air at a pressure of 700 kPa.
Compressors shall be equipped with an apparatus which removes water and oil from the compressed air. Where a primer is required,
it shall be applied before the supporting materials are installed.
After the joints have been finally cleaned and the primer (if any) has been applied, a supporting backing cord shall be installed by means
of an approved rolling tool in the prescribed positions. Where the joints are dirty, wet or moist, the supporting material shall be removed,
the joints cleaned and dried, and fresh material applied.
The procedure(s) to be followed by the Contractor to prevent the sealant from being spilt onto the concrete pavement shall be subject
to approval by the Engineer. The silicone sealant shall be pumped continuously directly into the joints with a suitable pneumatically
driven pump. Sealing shall be done from the upper surface of the supporting material. Immediately after installation and before a skin
appears, the surface of the sealant shall be worked to compact the sealant and to press it against the sides of the joint so as to ensure
that the prescribed clearance under the road surface is obtained. As an alternative to separate installation and finishing of the sealant,
an approved injection nozzle incorporating a finishing apparatus may be used, in which case only closed-cell polyethylene may be used
as supporting material. Further directions supplied by the manufacturer shall be strictly complied with, particularly with regard to
temperatures for application, opening to traffic, and safety aspects. No traffic shall be permitted to pass over a sealed joint before the
sealant is able to withstand the penetration of foreign matter.
The top surface of the sealant shall not be less than 5,0 mm and not more than 7,0 mm below the paved surface. All surplus sealant
and other foreign matter shall be removed from the concrete pavement surface in accordance with the directions of the manufacturer
of the sealant.
b) Liquid sealant for joints between concrete and asphalt pavements
These joints shall be sealed with a hot-poured joint-sealing compound as specified in Clause A6.1.5.7c). Prior to application, the joints shall be clean
and free from water. Curing compound adhering to joint walls shall be removed by sandblasting or with an abrasive wheel. Dirt, dust and laitance
shall be blown out of the joint with oil-free compressed air at a pressure of at least 700 kPa immediately before the sealing operation. The sealant
shall be applied in accordance with the manufacturer's instructions, particularly in regard to the temperature of application, which shall be strictly
controlled.
A6.1.8 WORKMANSHIP
a) Process control
The Contractor shall conduct all and a sufficient number of tests necessary for ensuring compliance with the requirements, as specified in this
Chapter, during all phases of the work. Accelerated 20-hour compressive-strength tests as described in Clause A20.1.5.16 of Chapter 20 shall be
conducted regularly with a view to predicting the 28-day compressive strength of the concrete in consultation with the Engineer. Where the
accelerated tests indicate that the required 28-day compressive strengths will not be attained, the Contractor shall immediately effect the necessary
changes to the materials and/or mix proportions in order to ensure that further work will comply with the requirements.
b) Acceptance control
Routine inspection and testing will be carried out by the Engineer to determine whether the quality of materials and workmanship complies with
the requirements of this section. The lot sizes and sampling for compressive strength shall be done in accordance with Clause A20.1.7 of Chapter
20, using Judgement Plan B as stated in Clause A20.1.7.5b)(ii) of Chapter 20 for acceptance control. The assessment of test results and
measurements shall be done in accordance with the provisions of Chapter 20 as relevant. In addition to the above, the following shall also apply:
(i) The Engineer may, at his discretion, decide to use the Contractor's test results in the judgement plan if he is satisfied that the Contractor has
complied with all the process control requirements.
(ii) The relationship between the 28-day compressive and the 28-day flexural strengths of the concrete established by the preliminary tests shall be
monitored during paving operations by regular tests at the discretion of the Engineer.
(iii) For this purpose sets of three beams and three cubes shall be manufactured from the same batch of concrete and tested for flexural and
compressive strength respectively. If the test results indicate a relationship which deviates from that established by the preliminary tests, the
specified compressive strength, as specified in Clause A6.1.4.2 shall be adjusted accordingly.
(iv) Where air entrainment has been included in the specification, and any test for air content shows a value falling outside the specified limits, the
quantity of air-entraining agent added to the concrete mix shall be adjusted, until the air content of the concrete is within the specified limits.

c) Construction tolerances
The work in this Chapter shall be constructed to the tolerances given below.
(i) Level and grade
The lot shall comply with the requirements specified if at least 90 % of all levels are within the H90 tolerance of 15 mm before any
level correction is made. Individual spots where levels deviate by more than the H max tolerance of 20 mm shall be repaired as
agreed to by the Engineer to bring the levels within the H90 tolerance.
The levels shall be taken in a random pattern or as directed by the Engineer, before and after the concrete layer has been
constructed, at exactly the same positions. The number of measurements representing the lot shall be a minimum of 30 or more.
(ii) Layer thickness

Layer thickness shall be established from the difference in actual levels as measured before and after the concrete layer has be
constructed as described in Clause A6.1.8c)(i) above. In addition to the thickness from levels, the Engineer can request for cores
from the lot where the average of 4 measurements per core will be reported for thickness at the position of the core.
The layer shall comply with the requirements specified if at least 90 % of the thickness measured for the lot:
- are equal to or thicker than the specified thickness minus the D90 tolerance of 14 mm
- the mean layer thickness for the lot is not less than the specified thickness minus the Dave tolerance of 1,0 mm and
- individual spots where the thickness is less than the specified thickness minus the Dmax tolerance of 18 mm be repaired as
agreed to by the Engineer to bring them within the D90 tolerance.
(iii) Grade
Deviations from the specified longitudinal grade on account of deviations from the specified levels shall not exceed those relevant
requirements given in Chapter 5.
(iv) Width of pavement
The average width shall be at least equal to the specified width and the edge of the pavement shall not deviate by more than 25
mm from the specified positions.
(v) Joints
Joints shall not deviate by more than 10 mm from their specified positions in the pavement or by more than 10 mm from the edge
of a 3,0 m straight-edge placed so as to touch the line of the joint. Neither shall the line of a joint be discontinuous. The tolerance
for the groove width of sawn joints shall be as follows:
- Longitudinal hinge joints ± 0,5 mm
- Transverse contraction joints ± 0,5 mm
(vi) Cross section
When tested with a 3,0 m straight-edge placed at right angles to the road centre line, the surface shall not deviate from the bottom
of the straight-edge by more than 6,0 mm.
(vii) Surface regularity
Surface regularity or roughness can be measured using one or a combination of instruments, as specified in the Contract
Documentation viz:
- Inertial High speed profilometers (IRI)
- Direct Contact Devices (IRI)
- Rolling straight edge

1. Inertial Profiler
The operations and calculations in Average 100 meter IRI values for three runs are in accordance with Clause A20.1.5.5c)(ii) of
Chapter 20.The assessment of the data for compliance shall be in accordance with Clause A9.1.8.4 of Chapter 9.
2. Direct Contact Device
The operations and calculations in Average 100m IRI values shall be in accordance with Clause A20.1.5.5(c)(i) of Chapter 20. The
assessment of the data for compliance is in accordance with Clause A9.1.8.4 of Chapter 9.
3. Rolling Straight Edge
The equipment is operated and calibrated in accordance with method ST3 of TMH6.The number of irregularities in excess of a
setting of 3,0 mm shall not exceed 8 over 100 m sections and not exceed an average number of 5 per 100 m taken over 300 – 600
meter sections. Any individual irregularity when measured with the rolling straight edge or a 3,0 m straight edge when laid parallel
to the road centre line shall not exceed 7,0 mm.
(viii) Dowels
Dowels shall be positioned at the depth specified, measured from the surface level of the slab, within a tolerance of ± 10 mm. They
shall be aligned parallel to the finished surface of the slab, to the centreline of the carriageway and to each other within the following
tolerances:

1. Dowels supported on cradles, prior to construction of the slab:
All dowels in a joint shall be within ± 2,0 mm per 300 mm length of bar. No individual dowel shall differ in alignment from an adjoining
bar by more than 3,0 mm per 300 mm length of bar in either the horizontal or vertical planes.
2. Dowels supported on cradles or mechanically installed, after construction of the slab.
Dowels in a joint shall be within ± 2,0 mm per 300 mm length of bar. No individual dowel shall differ in alignment from an adjoining
bar by more than 6,0 mm per 300 mm length of bar in either the horizontal or vertical planes.
3. All dowels shall be equally positioned about the intended line of the joint within a tolerance of ± 25 mm.
4. Random checks of the dowels positioning shall be ordered by the Engineer by taking cores at the position of the bar ends. The
coring shall be measured and paid for separately.
d) Unacceptable work or materials
(i) General
Any work or materials which does not comply with the specified requirements shall be removed and replaced with work, or materials,
which comply with all the requirements. If the Engineer so approves, the defects shall be repaired as specified in Chapter 7:
Maintenance and Repair of Concrete Layers, relative to the defects identified.
(ii) Acceptance of concrete of inferior strength or thickness at reduced payment
In lieu of requiring the removal of work that has been rejected on account of insufficient strength or thickness, the Engineer may accept
such work at his sole discretion, at reduced payment for the pavement concrete, on the following conditions:
Where concrete is deficient in thickness or in strength, the reduced payment shall be calculated in accordance with the following formula:
P = (dw)5 (fw)4 X 100
(ds)5 (fs)4
where P = percentage of normal compensation
dw = actual average thickness of slab
ds = specified average thickness of slab
fw = actual 28-day compressive strength of slab (average of 28-day compressive-strength tests)
fs = specified 28-day compressive strength of slab (La) in accordance with Chapter 20.
The above shall be subject to the rejection of a pavement with an average thickness of less than 93,1 % of the specified thickness or a
strength of less than 91,5 % of the specified strength, as determined above. Where both thickness and strength are deficient, it will be
rejected if P is less than 70 %. Where P exceeds 100 %, normal compensation only will be payable.
(iii) Any other deficiencies.
Any other deficiencies not accepted by the Engineer shall be repaired in accordance with Chapter 7: Maintenance and Repair of
Concrete Layers, as approved by the Engineer.

B6.1 PAVER LAID CONCRETE LAYERS
CONTENTS
B6.1.1 SCOPE
B6.1.2 DEFINITIONS
B6.1.3 GENERAL
B6.1.5 MATERIALS
B6.1.8 WORKMANSHIP
B6.1.1 SCOPE
This Section covers all the material requirements and work pertaining to the construction of concrete layers utilising predominantly labour
enhanced methods for the following pavement types:
- Jointed concrete pavement (JCP- Plain), with or without dowels

- Continuously reinforced concrete (CRCP)
It includes, inter alia, the specifications for materials, manufacture and construction requirements as relevant to the specific pavement as
prescribed.
This Chapter does not apply to the large-scale rehabilitation of concrete pavements, which is covered in Chapter 7: Maintenance and Repair of
Concrete Layers.
B6.1.2 DEFINITIONS
The definitions as listed in Clause A6.1.2 shall be applicable.
B6.1.3 GENERAL
B6.1.3.1 Quality plan
Prior to commencing with any permanent works, the Contractor shall submit a Quality Plan, for approval by the Engineer, detailing all methods
checks and hold points relating to construction of the specified product.
B6.1.3.2 Trial sections

Where so provided for in the pricing schedule, the Contractor shall construct a trial section for each pavement type specified. The location and
area of the trials shall be as directed by the Engineer. The purpose of the trial is for the Contractor to demonstrate that the equipment and
processes that he proposes to use will enable him to construct the particular concrete layer in accordance with all the specified requirements. The
Contractor shall calibrate the equipment and refine the mix design and construction process at his own cost.
The Contractor may, unless advised of any deficiencies in the trial section, proceed with the construction of the pavement ten days after the completion
proceed with the construction of the pavement ten days after the satisfactory completion and acceptance of the second or subsequent trial section.
work.
B6.1.3.3 Weather limitations


B6.1.4.1 General
All the requirements of Clause A6.1.4.1 shall be applicable.
B6.1.4.2 Design requirements

All the requirements as specified in Clause A6.1.4.2 shall be applicable with the exception that the mix proportions and consistency of the concrete
mix shall be such that, with the methods and equipment in use, the concrete can be adequately transported, discharged, spread and fully
consolidated without excessive bleeding or segregation of the components. The concrete consistency shall be appropriate to the type of paving
equipment used, the haul, the weather and the site conditions.
B6.1.4.3 Design procedure

All the requirements as specified in Clause A6.1.4.3 shall be applicable.
B6.1.5 MATERIALS
B6.1.5.1 Cementitious materials
All the requirements specified in Clause A6.1.5 shall apply. The cementitious materials incorporated in the mix shall, however, be such that,
dependant on the production rates achieved, the concrete shall have sufficient time to be transported, placed consolidated and finished prior to
initial setting occurring.
B6.1.5.2 Water
Water for washing aggregates, mixing concrete, and curing shall comply with the requirements in Clause A6.1.5.2.
B6.1.5.3 Aggregates for concrete

B6.1.5.4 Reinforcing steel, tie-bars and dowels

B6.1.5.5 Curing compound

All requirements as specified in Clause A6.1.5.6 shall be applicable.
B6.1.5.6 Materials for joints

All the material requirements for joints as specified in Clause A6.1.5.7 shall be applicable.

B6.1.6.1 General
The Contractor shall ensure the equipment and tools intended for use shall meet the following:
- The capability for handling the proposed materials and performing all parts of the work within the specifications.
- Production rates of such capacity that the paving operation proceeds continuously and at a constant rate of production, with starting and
stopping reduced to a minimum.
Before any concrete may be cast, the Engineer shall approve the concrete source, batching methodology, all assembled side-forms, guide wires
and/or rails and the paving train configuration. For this purpose the Engineer shall be given sufficient notice and opportunity. Approval by the
Engineer shall not relieve the Contractor of any of his obligations to construct the concrete pavement in accordance with the specified quality,
dimensions and relevant tolerances.
B6.1.6.2 Concrete batching plant

Where concrete is batched on site it must comply with the requirements of SANS 50206 (SANS 878). The Contractor shall have full responsibility to
implement process control testing in accordance with the specifications.
B6.1.6.3 Paving
a) Side forms
Before any side-forms may be ordered or brought onto the site, particulars regarding the side-forms shall have been approved by the Engineer.
Side-forms and rails shall be so designed, manufactured, set and supported that the completed concrete pavement will comply with all the
requirements of Clause A6.1.8. When assessed with a 3,0 m straight-edge, the top edge of the form shall not deviate by more than 3,0 mm at
any place, and the sides by more not than 6,0 mm. The sides shall not deviate by more than 3,0 mm from the vertical. The height of the side-
forms shall not be less than the nominal thickness of the concrete slab less 15 mm.
b) Paving equipment
The paving equipment is not prescribed but the Contractor shall utilise appropriate hand operated equipment and construction methods in order
to achieve the desired final product as specified. The Contractor shall provide a comprehensive method statement and quality plan to the Engineer
for approval prior to commencing with any such work.

The equipment shall be of such dimensions and arrangement so as to cover the full width of the pavement strip being placed.
B6.1.6.5 Burlap drag equipment

The burlap drag shall be either attached to a suitable apparatus running on the side forms as prescribed in Clause A6.1.6.5, or fixed to a sufficiently
rigid rod capable of being dragged across the full width of the pavement by labour located on either side of the side forms. When not in use, the
entire drag shall be lifted clear off the pavement.
The dimensions of the burlap drag shall be such that at least 1,0 m of the material is in contact with the surface of the concrete pavement measured
in the direction in which the drag is being moved. The burlap drag shall consist of at least two layers of approximately 340 g/m2 burlap with the
bottom layer at least 150 mm longer than the top layer at the dragging end. However, if the required texture is not obtained then, at the discretion
of the Engineer, the number of layers may be increased to four. The transverse threads of the trailing 150 mm to 300 mm of the burlap drag shall
be removed.
B6.1.6.6 Texture grooving equipment

Where texture grooved finish is specified, whether textured by machine or hand, the requirements shall be such that the specified texture is
achieved. The requirements for the grooving/texturing tines shall be as specified in Clause A6.1.6.6.
Where so specified in the Contract Documentation, the fresh concrete shall be broom textured utilising appropriate equipment just prior to applying
the curing compound.
B6.1.6.7 Applicator for curing compound membrane

Hand operated power-spray equipment may be used to apply specified curing compound.

B6.1.7.1 Preparing the Underlying Layers
The requirements as listed in Clause A6.1.7.1a), b) and c) shall be applicable.
B6.1.7.2 Batching and mixing of concrete

The requirements as listed in Clause A6.1.7.2 shall be applicable.
B6.1.7.3 Placing, Compacting and Finishing Concrete

a) General
All the requirements as listed in Clause A6.1.7.3 shall be applicable, with the following are additional requirements.
b) Placing of concrete
Where concrete is delivered from the side of the pavement by means of transit mixes, the distribution from the chute shall be such that lateral
movement of the concrete by labour shall be as minimal as possible in order to prevent segregation occurring.
Where concrete is delivered in tipper trucks ahead of the paving operation, the rate and manner of tipping shall be such as to prevent a height of
greater than 500 mm in the deposited pile having to be redistributed by hand.
c) Fixing of steel
Where the concrete is to be spread and initially levelled by hand, the type and spacing of supporting spacer blocks/stools, and installation detail
of any tie bars, dowels, continuous reinforcing steel or steel mesh shall be such that their final position shall not deviate from specified location
tolerances, as specified, during placement and distribution by labour based methods. The method to ensure this shall be approved by the Engineer.
d) Texturing and curing
Sufficient gang planks of appropriate rigidity shall be supplied to enable the workman to access the centre of the pavement in order to complete
the texturing and application of curing compound without disturbing the burlap finished surface.
In order to ensure straight grooves the comb shall be operated against a straight-edge placed at right angles to the pavement centre line. The same
requirements regarding groove dimensions or texture depth as for machine-texturing shall apply.
B6.1.7.4 Joint forming

All joints shall be formed in accordance with the requirements listed in Clause A6.1.7.4 as relevant.
B6.1.8 WORKMANSHIP
Unless otherwise specifically stated in the Contract Documentation, all the requirements specified in Clause A6.1.8 shall be applicable.

C6.1 PAVER LAID CONCRETE LAYERS
(i) Preamble
equipment, labour, tools, incidentals and supervision necessary to carry out the activity or construct the works under the relevant pay item, unless
otherwise stated.
No extra over payment shall apply to work carried out in restricted areas for work carried out in conformance to this Chapter. The rates tendered
for the payment items in this Chapter shall include full compensation for any work in restricted areas.
Not applicable.
2. No separate payment will be made for the protection or repair as required of any existing or new road furniture, structures, buildings, infrastructure
or services damaged by the Contractor’s activities.
pay items.
5. No separate payment will be made for the hauling of any materials where the material is moved over a distance of less than, and up to 1,0 km.

Loading and hauling C6.1
items

C6.1.1 Construction of trial section (Complete: including texturing and curing)
C6.1.1.1 Mechanical construction (state pavement type and nominal thickness) square metre (m²)
C6.1.1.2 Labour enhanced construction (state pavement type and nominal thickness) square metre (m²)
The unit of measurement for the trial pavement shall be the square metre of completed trial section. Not more than a total length of 200 m of paver
laid trial pavement and not more than 60m of manually constructed trial pavement shall be measured for payment as described in Clause A6.1.3.2.
C6.1.2 Construction of jointed concrete pavement (JCP) (Excluding texturing and curing)
C6.1.2.1 JCP without dowels:
(a) Paver laid construction (state nominal thickness) square metre (m²)
(b) Labour enhanced construction (state nominal thickness) square metre (m²)

C6.1.2.2 JCP with dowels:
C6.1.2.3 Additional concrete placed to thicken up the slab at joints as specified in the Contract cubic metre (m³)
Documentation
C6.1.3 Construction of continuously reinforced concrete pavement (Excluding texturing and

curing)
C6.1.3.1 Continuously reinforced concrete pavement (CRCP):
The unit of measurement for payment items C.6.1.2 to C6.1.3 shall be the square metre of concrete pavement placed and finished in accordance with
the Contract Documentation. The quantity shall be calculated from the authorised dimensions of the completed surface, except when the Engineer
requires or the drawings show local deviations from the specified thickness, such as at bridge approach slabs. The volume of concrete in such cases
shall be converted into an equivalent area in square metres based on the specified thickness of the slab.
The tendered rate shall include full compensation for procuring and furnishing all the materials, storing the materials, providing all plant, determining
the mix proportions, mixing, transporting, placing and finishing the concrete, including formwork, repairs done to defective work, protecting the
pavement against damage, construction joints and process control.
The tendered rate shall also include full compensation for the provision of any additional width required by the Contractor to the earthworks and/or
pavement layers to suit the particular requirements of the paving equipment. It shall also include full compensation for the removal of the additional
widening which extends beyond the limits of the specified cross-section.
The quantity of additional concrete over and above the specified layer thickness and required at thickened joints shall be the cubic metre of concrete
determined from the dimensions as detailed in the Contract Documentation.
The tendered rates shall also include full compensation for constructing concrete pavements which cannot be constructed with conventional plant, as
envisaged in this Chapter.
C6.1.4 Texturing and curing the concrete pavement
C6.1.4.1 Burlap-dragged and grooved texture:
(a) Paver constructed square metre (m²)
(b) Labour enhanced construction square metre (m²)
C6.1.4.2 Burlap-dragged and broom finish only square metre (m²)
C6.1.4.3 Curing:
(a) Paver constructed square metre (m²)
(b) Labour enhanced construction square metre (m²)
The unit of measurement for texturing and curing shall be the square metre of completed pavement which has received the specified surface texturing,
and which was cured as specified. The quantity shall be calculated from the specified horizontal dimensions of the completed concrete surface in the
case of texturing and from the specified horizontal dimensions of the completed concrete surface, plus the surface area of the slab sides, in the case
of curing.
The tendered rate for texturing shall include full compensation for providing the plant and equipment required and for applying the specified surface
texture.
The tendered rate for curing shall include full compensation for providing the curing compound and its application as specified at the specified nominal
rates of application by means of an approved pressure distributor. The tendered rate shall also include compensation for spraying the curing compound
in unsealed joints after the sawing has been completed.
C6.1.5 Variation in the rate of application of the curing compound litre (ℓ)
The unit of measurement in respect of increases or decreases in the rate of application of the curing compound from the nominal application as
specified, shall be the litre. Payment for variations shall be made as specified in Chapter 1.

C6.1.6 Joints
C6.1.6.1 Expansion joints complete (excluding dowels) metre (m)
C6.1.6.2 Longitudinal hinge joints:
(a) Sealed hinge joints (indicate type and reference to drawings) metre (m)
(b) Unsealed hinge joints (indicate type and reference to drawings) metre (m)
C6.1.6.3 Sealed transverse contraction joints sawn in two separate operations (widths as shown on metre (m)
the drawings)
C6.1.6.4 Dowel bars: mild steel inserted in new concrete (indicate diameter, length and position on
drawings):
(a) Inserted by mechanical dowel bar inserter number (No)
(b) Pre-installed on approved frame number (No)
C6.1.6.5 Tie-bars: installed in new concrete (indicate, diameter and length):
(a) Mild steel number (No)
(b) High tensile steel number (No)
C6.1.6.6 Forming and sealing joints between asphalt and concrete pavements metre (m)
The unit of measurement for joints in the pavement shall be the metre of completed joint, except that dowel bars and tie-bars across joints shall be
measured separately by the numbers of each type installed.
Construction joints as such shall not be measured for payment and their cost shall be deemed to be included in the rate tendered for the concrete
pavement. However, if the position of a longitudinal construction joint coincides with that of a hinge joint, the Contractor will be paid at the rate tendered
for the type of hinge joint replaced by the construction joint, provided that the requisite number and sizes of tie bars for the hinge joints are installed.
Where the hinge joint replaced by the construction joint is a sealed hinged joint, the construction joint shall be sawn and sealed, in which case the
Contractor will be paid at the tendered rate for sawn and sealed hinge joints.
The tendered rates for expansion joints shall include full compensation for forming the joint, complete with joint filler, rounding or chamfering the
corners (if required) and installing the seal.
The tendered rates for longitudinal hinge joints shall include full compensation for sawing the joint (if required) and supplying and inserting the seal (if
required).
The tendered rate for transverse contraction joints shall include full compensation for sawing the joint and installing the specified type of seal, including
appurtenant materials, and for temporarily sealing the joint with paper rope.
The tendered rates for dowel bars and tie-bars shall include full compensation for supplying, cutting, placing, holding the bars in position, including a
supporting framework or cradles where required, and fixing the end caps and bond breaking materials to dowels.
The tendered rate for forming and sealing the joints between asphalt and concrete pavements shall include full compensation for supplying all the
necessary plant and materials, for forming a joint to the required dimensions in the asphalt seal, cleaning the joint and sealing as specified in Clause
A6.1.7.5b)
C6.1.7 Steel reinforcement in concrete pavements
C6.1.7.2 High tensile steel bars ton (t)
The unit of measurement for steel bars shall be the ton of reinforcing steel in place in accordance with the drawings or as authorised.
The unit of measurement for welded steel fabric shall be the kilogram of welded steel fabric in the panels of concrete paving which require non-
contiguous reinforcement as specified. The quantity shall be calculated from the area of the mesh used in accordance with the drawings or as
authorised.
The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding, placing and fixing the steel reinforcement,
including all tying wires, spacers and waste.

C6.1.8 Drilling of testing of cores
C6.1.8.1 100 mm cores drilled from pavement for testing of compressive strength number (No)
C6.1.8.2 150 mm cores drilled from pavement for testing of compressive strength number (No)
The unit of measurement shall be the number of cores drilled or drilled and tested on the instruction of the Engineer. Cores drilled by the Contractor
at his own initiative as part of his process control, or for testing cracks sealed at the Contractor's own cost, shall not be measured for payment.
The tendered rates shall include full compensation for drilling the cores and, where applicable, having them tested by an approved laboratory, and for
all labour, transport, testing charges and other incidentals, save only the cost of providing a core-drilling machine on the site, which shall be paid for
separately. It shall also include compensation for restoring the concrete pavement where holes were drilled.

D6.1 PAVER LAID CONCRETE LAYERS
CONTENTS
D6.1.1 SCOPE
D6.1.2 GENERAL
Only for joint sealant

6.2 SEGMENTAL BLOCK PAVING LAYERS
CONTENTS
A 6.2.1 SCOPE
A 6.2.2 DEFINITIONS
A 6.2.3 GENERAL
A 6.2.4 DESIGN BY CONTRACTOR / PERFORMANCE BASED SYSTEMS
A 6.2.5 MATERIALS
A 6.2.6 CONSTRUCTION EQUIPMENT
A 6.2.7 EXECUTION OF THE WORKS
A 6.2.8 WORKMANSHIP

A6.2 SEGMENTAL BLOCK PAVING LAYERS

A6.2.1 SCOPE
This Section covers the furnishing of materials and the construction of segmental block paving for roads.
A6.2.2 DEFINITIONS
Segmental block paving – a system of individual shaped blocks arranged to form a continuous hard-wearing and durable surface overlay.
A6.2.3 GENERAL

Where it is specified in the Contract Documentation that the blocks shall be manufactured in a dedicated on-site facility by the Contractor, all the
requirements as listed in SANS 1058 for the specific class of block specified shall be applicable.
A6.2.5 MATERIALS
A6.2.5.1 Paving blocks
Concrete paving blocks shall comply with the requirements of SABS 1058. The block shall be of the class, type and thickness specified in the Contract
Documentation. The surface texture and colour of all blocks shall be uniform.
A6.2.5.2 Bedding sand

Bedding sand shall not contain any silt, clay or other deleterious impurities. The sand shall comply with the following grading requirements in Table
A6.2.5-1.
Table A6.2.5-1: Grading requirements for bedding sand
Sieve size (mm) Percentage passing by mass
7,1 100
5,0 95 – 100
2,0 80 – 100
1,0 50 – 85
0,600 25 – 60
0,300 10 – 30

0,150 5 – 15
0,075 0 - 10
A6.2.5.3 Jointing sand

100 % of the sand used to fill the joints between the concrete blocks shall pass through a 1,0 mm sieve and between 10 % and 15 % of it shall pass
through a 0,075 mm sieve.
A6.2.5.4 Concrete beams, kerbs and channelling

Cast in situ concrete edge beams or intermediate beams shall be constructed in accordance with the provisions of Chapter 13: Structures, as relevant.
Prefabricated kerbing and channelling shall comply with the requirements of Section A3.3 or Section B3.3 of Chapter 3 as specified in the Contract
Documentation.
A6.2.5.5 Herbicide and ant poison

The herbicide and ant poison shall be environmentally friendly and shall be subject to the Engineer's approval.

A suitable vibrating-plate compactor shall be supplied operating at a frequency of 65 Hz to 100 Hz and a low amplitude. Its plate surface shall be
0,2 m2 to 0,4 m2 and it shall develop a centrifugal force of 7 kN to 16 kN..

A6.2.7.1 Preparing the underlying layers
The underlying pavement layer/s shall be as specified in the Contract Documentation. The underlying pavement layers shall be constructed and
prepared in accordance with the requirements for the relevant pavement layers in Chapters 4 and 5 of these specifications, or as may be specifically
otherwise prescribed in the Contract Documentation. Where specified by the Engineer the prepared surface shall be treated with approved herbicide
and ant poison before the layer of sand for bedding is placed.
A6.2.7.2 Concrete edge and intermediate beams

Cast in situ or prefabricated concrete edge beams or intermediate beams shall be constructed on the underlying pavement layer in accordance with
the details shown on the drawings. No paving blocks shall be laid before the edge and intermediate beams have developed sufficient strength to
withstand the construction forces.
A6.2.7.3 Bedding sand

A layer of bedding sand complying with the requirements of Clause A6.2.5.2 shall be placed on top of the prepared surface of the underlying pavement
layer. It shall be accurately levelled to an un-compacted thickness of 25 mm (± 5,0 mm), or as specified, so that the concrete paving blocks will have
the correct level after compaction. The bedding sand shall be placed immediately before the concrete paving blocks are laid and shall be allowed to
dry out to permit upward creep during compaction. The sand shall not be compacted before the blocks have been laid.
A6.2.7.4 Laying of the blocks

The blocks shall be laid in the pattern shown on the drawings or as directed by the Engineer. Unbroken blocks shall be laid first and the filler pieces
afterwards. Filler pieces shall be neatly sawn or hewn to fit exactly into the space to be filled. Any space of which the size is less than 25 % of the
size of an unbroken block, shall be filled with 35 MPa concrete. The size of the joints between blocks shall be between 2,0 mm and 4,0 mm, and the
top faces of the blocks shall be flush.
After the paving blocks have been laid, the pavement shall be compacted by two passes of a suitable vibrating-plate compactor operating at a
frequency of 65 Hz to 100 Hz and a low amplitude.
After compaction of the pavement as described above, jointing sand shall be spread and brushed into the joints until the joints have been properly
filled. Any surplus sand shall then be broomed off and the pavement shall then be subjected to two further passes by the plate vibrator. Jointing sand
shall not be hosed into the joints. The block paving shall be inspected after 2 months, and the joints shall be resanded where required.
A6.2.8 WORKMANSHIP
The completed concrete block paving shall comply with the following construction tolerances:
a) Line of pattern
(i) Maximum deviation from a 3,0 m straight edge: 3,0 mm
(ii) Maximum deviation from a 20 m straight line: 10 mm
b) Vertical deviation from a 3,0 m straight edge
(i) At the edge beams: 3,0 mm
(ii) Elsewhere: 3,0 mm
c) Differences in the surface levels of adjacent units: 2,0 mm

B6.2 SEGMENTAL BLOCK PAVING LAYERS
CONTENTS
B6.2.1 SCOPE
B6.2.2 DEFINITIONS
B6.2.3 GENERAL
B6.2.5 MATERIALS
B6.2.8 WORKMANSHIP
B6.2.1 SCOPE
B6.2.2 DEFINITIONS
The definitions as in Clause A6.2.2 shall apply.
B6.2.3 GENERAL

B6.2.5 MATERIALS


B6.2.8 WORKMANSHIP

C6.2 SEGMENTAL BLOCK PAVING LAYERS
(i) Preamble
otherwise stated.
Not applicable.
pay items.
specifications.

Prefabricated concrete kerbing and channelling C6.2.2
items

C6.2.1 Segmental block paving
C6.2.1.1 Concrete block paving (indicate class, type and thickness of blocks) square metre (m²)
The unit of measurement shall be the square metre of completed concrete block paving. The quantity shall be calculated from the dimensions
shown on the drawings or authorised by the Engineer. The tendered rate shall include full compensation for furnishing all materials,
constructing the sand bedding, laying and compacting the concrete pavement blocks, filling the joints with jointing sand and for all other work
necessary to complete the concrete block paving as specified.
The tendered rate shall include full compensation for furnishing all materials, constructing the sand bedding, laying and compacting the
concrete pavement blocks, filling the joints with jointing sand, and for all other work.

C6.2.2 Cast in-situ concrete edge and intermediate beams cubic metre (m³)
The unit of measurement shall be the cubic metre of concrete placed in edge and intermediate beams. The quantity shall be calculated from
the dimensions shown on the drawings or as authorised by the Engineer.
All prefabricated concrete kerbing and channelling shall be measured and paid for under Part C, Section C3.3 of Chapter 3 as relevant.
The tendered rate shall include full compensation for furnishing all materials, and constructing the edge and intermediate beams complete
as specified, including all excavation and backfilling in all classes of material.
C6.2.3 Provision and application of approved herbicide and ant poison.
C6.2.3.1 Provision of materials prime cost sum
C6.2.3.2 Contractor’s charges and profit added to the prime cost sum percent (%)
Payment under the prime cost sum for providing ant poison and herbicide and the Contractor's costs and profit in this respect shall be made
in accordance with the provisions of the general conditions of contract, but, in addition, the Contractor's tendered rate for costs and profit
shall include full compensation for applying the chemicals as specified.
C6.2.4 Re sanding of joints in segmental block paving
C6.2.4.1 Concrete block paving (indicate class, type and thickness of blocks) square metre (m²)
The unit of measurement shall be the square metre of completed concrete block paving where re-sanding (filling) of the jointing sand is
required after initial completion of the work. The quantity shall be calculated from the dimensions shown on the drawings or authorised by
the Engineer. The tendered rate shall include full compensation for furnishing all materials to refill the joints with jointing sand where required.

D6.2 SEGMENTAL BLOCK PAVING LAYERS
CONTENTS
D6.2.1 SCOPE
D6.2.2 GENERAL


South Africa
COTO
Officials


CHAPTER 7: MAINTENANCE AND REPAIR
OF CONCRETE LAYERS
October 2020

FOREWORD

Published by:

industry.
Document versions:
Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 7: MAINTENANCE AND REPAIR OF CONCRETE LAYERS .................................................... 7-1

7.1 REPLACEMENT OF EXISTING JOINT SEALANT ................................................................................. 7-1
PART A: SPECIFICATIONS ................................................................................................................................................................. 7-1
PART B: LABOUR ENHANCEMENT .................................................................................................................................................... 7-3
PART C: MEASUREMENT AND PAYMENT ........................................................................................................................................ 7-4
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES ........................................................................................................... 7-6
7.2 REPAIR TO EXISTING JOINTS AND UNCONTROLLED CRACKS IN CONCRETE PAVEMENTS .. 7-12
PART A: SPECIFICATIONS ............................................................................................................................................................... 7-12
PART B: LABOUR ENHANCEMENT .................................................................................................................................................. 7-19
PART C: MEASUREMENT AND PAYMENT ...................................................................................................................................... 7-20
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES ......................................................................................................... 7-23
7.3 REMOVAL AND REINSTATEMENT OF EXISTING CONCRETE LAYERS ........................................ 7-24

7.4 REINSTATEMENT OF SLAB SUPPORT BY GROUT INJECTION ..................................................... 7-38

7.5 REINSTATEMENT OF RIDING QUALITY ............................................................................................. 7-45

7.6 REINSTATEMENT OF SURFACE TEXTURE ....................................................................................... 7-50

CHAPTER 7: MAINTENANCE AND REPAIR OF CONCRETE LAYERS
7.1 REPLACEMENT OF EXISTING JOINT SEALANT
CONTENTS
A7.1.1 SCOPE
A7.1.2 DEFINITIONS
A7.1.3 GENERAL
A7.1.5 MATERIALS
A7.1.8 WORKMANSHIP

A7.1 REPLACEMENT OF EXISTING JOINT SEALANT

A7.1.1 SCOPE
This Section covers work related to:
- The removal and replacement of existing joint sealants in concrete pavements where no repairs to the adjacent concrete is required.
- Joint sealant installed under a Performance Based System with extended warranties is covered under Part D of this Chapter.
A7.1.2 DEFINITIONS
The definitions relating to concrete layers as stated in Chapter 6 shall also be applicable to this Chapter 7.
Joint sealants - cold poured self-levelling silicone liquid sealant for sealing joints in concrete.
Types of joints and associated pavement distress - as defined in the latest version of TMH9: Standard Visual Assessment Manual, Part C:
Concrete Pavements.
A7.1.3 GENERAL
The existing joint sealant shall be removed and the joint shall then be reamed, cleaned and the new sealant installed in accordance with the Contract
Documentation.
The Contractor shall submit a complete method statement for approval by the Engineer before the resealing of any joints commences. The Engineer
will have 5 days to study and comment on the method statement before approval shall be given.

Unless prescribed as part of a performance guarantee system as specified in Part D, the joints shall be formed and sealed in conformance to the
specified requirements in Clause A6.1.5 of Chapter 6 and Chapter 7 as applicable.
A7.1.5 MATERIALS
A7.1.5.1 Sealant
The joint sealant shall be a cold poured self- levelling liquid silicone sealant conforming to the requirements as prescribed in Clause A6.1.5.7 of
Chapter 6 for the particular type of sealant specified.

The equipment required shall be appropriate to the work to be completed in accordance with the prescribed requirements and construction tolerances
permitted.

The execution of the work shall be as specified below for the various types of treatments listed:
A7.1.7.1 Removal of existing seals, reaming of joint and resealing

The reaming and sealing of existing joints shall be undertaken in accordance with Clause A6.1.7.5. In addition, this treatment is applicable where
existing joints are only slightly spalled and no treatment of the adjacent concrete is required. The existing joint seals and backing material shall
be removed from the joints. The joint grooves shall be reamed to their prescribed final dimensions. They shall then be cleaned by means of a high
pressure jet of water over the full depth of the joints to remove all fine matter and to produce dust-free joint grooves. Immediately before the supporting
material is installed, the grooves shall be dried by means of oil-free compressed air at a pressure of 700 kPa. Compressors shall be equipped with
an apparatus which removes water and oil from the compressed air. Where a primer is required by the manufacturer, it shall be applied before the
backing materials are installed.
After the joints have been finally cleaned and the primer (if any) has been applied, a supporting backing cord shall be installed by means of an approved
rolling tool in the prescribed positions. Where the joints are dirty, wet or moist, the supporting material shall be removed, the joints cleaned and dried,
and fresh material applied.
The silicone sealant shall be pumped continuously directly into the joints with a suitable pneumatically driven pump. Sealing shall be done from the
upper surface of the supporting material. Immediately after installation and before a skin appears, the surface of the sealant shall be worked to
compact the sealant and to press it against the sides of the joint so as to ensure that the prescribed clearance under the road surface is obtained. As
an alternative to separate installation and finishing of the sealant, an approved injection nozzle incorporating a finishing apparatus may be used, in
which case only closed-cell polyethylene may be used as supporting material. Further directions supplied by the manufacturer shall be strictly complied
with, particularly with regard to temperatures for application, opening to traffic, and safety aspects. No traffic shall be permitted to pass over a sealed
joint before the sealant is able to withstand the penetration of foreign matter.
The procedure(s) to be followed by the Contractor to prevent the sealant from being spilt onto the concrete pavement shall be subject to approval by
the Engineer. All surplus sealant and other foreign matter shall be removed from the concrete pavement surface in accordance with the directions of
the manufacturer of the sealant.
Seals shall only be removed immediately prior to the resealing operation and no sections of pavement shall be left unsealed while being trafficked
unless written permission has been obtained from the Engineer.
A7.1.7.2 Bevelling of spalled edges and resealing

This treatment shall apply to joints spalled to degrees of medium and high severity as defined in TMH 9. Existing seals shall be removed and the
joints reamed out to produce clean-cut surfaces as described in Clause A7.1.7.1 above. The edges of the joints shall then be bevelled by means
of a mechanical device to dimensions of 10 mm, 15 mm or 20 mm (dependant on the depth of the spall) at a 45° angle before the installation of
the liquid sealant as described in Clause A7.1.7.1.
A7.1.8 WORKMANSHIP
A7.1.8.1 Groove width
After reaming, the width and depth of the groove shall be ± 0,5 mm of that width specified in the Contract Documentation.
A7.1.8.1 Sealant depth

The top surface of the sealant shall not be less than 5,0 mm and not more than 7,0 mm below the paved surface.

B7.1 REPLACEMENT OF EXISTING JOINT SEALANT
CONTENTS
B7.1.1 SCOPE
B7.1.2 DEFINITIONS
B7.1.3 GENERAL
B7.1.5 MATERIALS
B7.1.8 WORKMANSHIP
B7.1.1 SCOPE
B7.1.2 DEFINITIONS
B7.1.3 GENERAL

B7.1.5 MATERIALS


B7.1.8 WORKMANSHIP

C7.1 REPLACEMENT OF EXISTING JOINT SEALANT
(i) Preamble
The tendered rate for each item shall include full compensation for providing, maintaining and decommissioning upon completion, all the plant,
equipment, labour, tools, incidentals and supervision necessary to carry out the activity and construct the works under the relevant pay item,
unless otherwise stated.
None.
pay items.
km.
C7.1.1 Replacing of joint sealant in existing concrete pavement as follows:
C7.1.1.1 Removal of existing seal and backing material metre (m)
C7.1.1.2 Reaming of existing joints (indicate width and depth) metre (m)
C7.1.1.3 Bevelling of one side of the joint to a dimension of 10 mm X 10 mm metre (m)
C7.1.1.4 Bevelling of both sides of the joint to a dimension of 10 mm X 10 mm metre (m)
C7.1.1.5 Installation of backing material in saw cut joints (to fit saw cut dimensions) metre (m)
C7.1.1.6 Installation of cold pour sealant litre (ℓ)
The tendered rate for the removal of the existing seal and backing material for C7.1.1.1 and 2 shall include full compensation for providing labour
and equipment required. The tendered rate shall also include for the disposal of the removed seal and backing material.
The unit of measurement for reaming of joints in existing concrete pavements shall be the metre of reaming of the existing joint.
The unit of measurement for bevelling shall be the metre (m) of bevelling undertaken at longitudinal and transverse joints and cracks. Distinction
shall be made between different sizes of bevelling and for bevelling on one or both sides of joints/cracks.
The tendered rate for bevelling and routing shall include full compensation for providing the plant and equipment required and for cutting the
bevels and rout grooves to the required dimensions indicted on the drawings as well as for the cleaning of the routed crack/joint by means of high
pressure water jetting followed by oil free high pressure air jetting prior to the installation of the back-up material or sealant.
The tendered rate for the installation of the back-up material shall include full compensation for providing the labour and equipment required. The
tendered rate shall also include for the cleaning of the joint by means of high pressure water jetting followed by oil free high pressure air jetting
prior to the installation of the back-up material.

The unit of measurement of cold poured liquid sealant shall be the litre () of cold-poured liquid sealant applied to the joint reservoir. The tendered
rate for cold-poured liquid sealants shall include full compensation for the supply and delivery of the materials to the point of installation and the
installation of the sealant. The tendered rate shall also include for the supply and application of joint primer to the vertical faces of the joint groove.
In measuring the liquid sealant (litres) the following two distinctions shall be made:
(i) Saw cut joints and/or cracks: Measurement shall be calculated in place to the dimensions specified on the drawings.
(ii) Routed joints/cracks: Measurement shall be calculated in accordance with the volume of the sealant supplied in drums (containers)
less 5 % to allow for shrinkage on curing.
C7.1.2 Costs incurred due to repair and monitoring in terms of Product Performance Lump sum
Guarantee System (PPGS)
The unit of measurement provides for the costs incurred by the Employer during monitoring and evaluation (after certificate of completion) for
assessments during the PPGS phases, i.e. work undertaken by the Engineer.

D7.1 REPLACEMENT OF EXISTING JOINT SEALANT
CONTENTS
D7.1.1 SCOPE
D7.1.2 DEFINITIONS
D7.1.3 GENERAL
D7.1.4 DESIGN BY CONTRACTOR / PERFORMANCE BASED SYSTEMS
D7.1.5 MATERIALS
D7.1.6 CONSTRUCTION EQUIPMENT
D7.1.7 EXECUTION OF THE WORKS
D7.1.8 WORKMANSHIP
D7.1.1 SCOPE
This Part deals with the installation of joint seals in terms of a Product Performance Guarantee System (PPGS). This Part shall also cover the re-
sealing of all joints in the longitudinal weakened plane, transverse and longitudinal contraction and longitudinal construction joints (where directed
by the Engineer) in the existing concrete pavement.
D7.1.2 DEFINITIONS
The definitions applicable to Clause A7.1.2 shall apply.
D7.1.3 GENERAL
This Section covers the specifications and work related to the functional condition of the liquid silicone, or such alternative product as may be
accepted by the Engineer, used for the sealing of saw cut joints in the longitudinal weakened plane, transverse contraction and longitudinal
construction joints in the concrete pavement in terms of a product performance guarantee.
The pre-treatment or accepted alternative specified herein shall in terms of this part of the specification automatically form part of the Product
Performance Guarantee System (PPGS).
The conditions contained in this section of the project document shall only be applicable to joints repaired under the contract with a cold poured
liquid sealant or such alternative product as may be accepted by the Engineer.
In support of any tender submitted either as proposed in these contract Documents, or as an alternative, the tenderer shall comply with the
followings additional requirements:
- Quality Assurance Plan
- Use of “Professional Partner”
- Design constraints for PPGS
- Technical report
D7.1.4 DESIGN BY CONTRACTOR / PERFORMANCE BASED SYSTEMS

A requirement of this contract shall be that the liquid sealant used in the joint grooves shall comply with a performance guarantee which shall be
subject to conditions stipulated in the special conditions and project specification.
The requirements to which the liquid sealant shall conform during the guarantee periods shall be in accordance with the functional conditions of
the sealant as described
D7.1.5 MATERIALS
D7.1.5.1 Materials for joints
Materials used for sealing of joints shall not be older than six (6) months. The age of sealant shall be certified by an approved testing facility.
The silicone sealant must be applied by means of pumping the sealant from a storage contained through compressed air powered pumping
equipment and applied to the joint slot by means of nozzles designed to ensure that the slot is filled with sealant as indicated on the drawings.
Application of the sealant to the joint slot by hand shall not be permitted.”

The Contractor shall provide all the necessary tools and equipment in order to complete the work in accordance with the guarantee requirements.

D7.1.7.1 Pavement description and extent of joint repairs covered by the PPGS
a) Definition of terms
The definition of terms used herein are in accordance withTMH9.
b) Description of the existing pavement, condition and related issues
Information pertaining to the above matters are contained in the Contract Documentation.
c) Methodology for joint resealing of the concrete pavement
All the transverse contraction joints together with the longitudinal weakened plane joints on the pavement are to be resealed under this contract.
The resealing of these joints is to prevent the infiltration of water and any incompressible material entering into the joint.
D7.1.8 WORKMANSHIP
D7.1.8.1 General
The onus rests entirely on the Contractor to produce work which conforms in quality to the specifications and requirements herein, or such other
specification and requirements as defined in the accepted tender that will perform in terms of the requirements of the Product Performance
Guarantee System (PPGS).
Any design constraints envisaged by the Contractor on the PPGS related product or alternative approved product shall be highlighted on the
relevant Returnable Schedules.
Furthermore, the Contractor shall, together with his programme of work stipulated in Chapter 1 as relevant, or at such time as approved by the
Engineer, submit proposals to the Engineer regarding the manner in which his quality management programme and testing frequencies are to be
undertaken.
The Engineer shall however, conduct such tests as he may deem applicable and shall retain all rights as determined in the General Conditions of
Contract related to bad workmanship or unacceptable materials. This shall also be applicable to accepted alternative material and related
specifications.
Any of the Engineers actions hereunder shall however not be construed to relive the Contractor of his responsibilities in terms of the PPGS
specified herein.
D7.1.8.2 Composition of visual assessment panel and reporting

The visual assessment of the condition of the liquid silicone or other approved sealant in the joints of the concrete pavement shall be undertaken
by means of a visual assessment panel comprising the following representatives:
• Employer 2 representatives
• Contractor 2 representatives
• Consulting Engineer or a suitably qualified external assessor 1 representative
The Contractor shall provide proof that his representatives are suitably qualified.
All site investigations or inspections and reporting by the panel of representatives shall be undertaken on a biannual basis within two months of
completion. The arrangements, responsibilities and costs for such inspections shall be vested with each party.
Reporting, which shall be the responsibility of the Contractor shall consist of the following:
• Completion and copying of report forms in accordance with the Employer’s requirements.
• Compiling of a report on finding as well as proposed remedial measures
The above-mentioned requirements shall be completed and delivered in triplicate to the office of the Employer within one calendar month of
inspections date.
D7.1.8.3 Types and definition of distress

a) Types of distress
The types of distress influencing the functional condition of the liquid silicone, or other approved sealant and which are to be monitored in terms
of this Chapter are as follows:
• Adhesion
• Cohesion
• Extrusion
• Weed growth
• Deformation

Distress to the liquid sealant as a result of mechanical damage shall not be classified as a type of distress in terms of the production performance
guarantee system.
b) Definition of distress
(i) Adhesion
This type of distress occurs when the liquid sealant has lost its bond with the joint face of the concrete pavement (i.e. no adhesion
between the liquid sealant and the joint face). In measuring this condition, distinction shall be made between loss of adhesion on
one side and loss of adhesion on both sides of the joint. The ruler test method as described in Chapter 20 shall be employed to
test the adhesion as described herein.
Should 20 % of the ruler be loose, the seal shall be noted as loose. The frequency of the ruler test per unit length shall be agreed
upon by the panel.
(ii) Cohesion
This type of distress occurs when the liquid sealant loses its elasticity and develops cracks in the seal itself while still being bonded
to the joint faces on either side of the crack. Should cracks be visible with the naked eye, the seal shall be noted as having poor
cohesion.
(iii) Extrusion
This condition occurs when the joint is devoid of any liquid sealant material (i.e. the liquid sealant is missing or loose on both sides).
(iv) Weed growth
This type of distress occurs when weed or any other form of vegetation/grass grows within the confines of the joint.
(v) Deformation
This type of distress occurs when the tooled surface of the liquid sealant takes on a damaged or deformed shape (i.e. an irregular
shape) while still being bonded to the joint faces of the concrete pavement.
c) Field measurements
(i) Frequency and documentation
The monitoring of the condition of the joint seals shall be undertaken on a biannual basis in the month of the completion of the
works and shall be carried out on portions of the whole of the works as directed by the Employer or his appointed representative.
The monitoring shall take place during times of peak traffic.
The first measurements shall be undertaken after the completion date of the contract and thereafter at two yearly intervals within
two months of the month of the first inspection up to the end of the guarantee period.
All measurements taken in terms of the above requirements shall be fully documented and kept in a place of safekeeping by the
Employer.
(ii) Position of measurements
The measurements of defective joint seals within a number of pre-determined sections of the road (positions of sections to be
determined by the panel) shall be determined by means of a visual inspection and tests of all transverse contraction joints,
longitudinal weakened plane joints and joints replaced under this contract within each predetermined section. In taking these
measurements, the following requirements shall be complied with:
1. The minimum length of a section shall be 200 m
2. Each carriageway shall be measured separately
3. The minimum length of any distress item to be measured and used in calculating the normal shall be as follows:
• 0,5 m for adhesion (one or both sides), cohesion, extrusion and deformation
• 0,3 m for weed growth
4. Longitudinal weakened plane joints, and transverse contraction joints shall be measured separately.
d) Evaluation of acceptance by Engineer
The following criteria shall be applied by the Engineer to determine the acceptance of the PPGS portion of the work to determine whether remedial
work is required to the PPGS portion of the work. These rules shall be applied after each of the assessments as appropriate.
(i) Assessment on completion of the work
An assessment shall be done on completion of the work and all defects must be repaired by the Contractor before a Certificate of
Completion will be issued. The Certificate of Completion shall only be issued after the Contractor has provided the Performance
Guarantee for the eight (8) year period.
(ii) Assessment after year two (2) of the Defects Notification Period
Should all parameters meet the full Acceptance Criteria, then the Engineer shall issue a report to the Contractor confirming the
results of the assessment and confirming that the first two years of the Defects Notification Period have been successfully
completed. The Employer will release the first of the performance guarantees provided by the Contractor.
Should one or more of the parameters fail to meet the full Acceptance Criteria, then the Engineer, in consultation with the Employer,
shall decide whether or not immediate remedial work will be required to be carried out at that stage. The Engineer shall issue a
report to the Contractor confirming the results of the assessment.
Should the Engineer, after consultation with the Employer, confirm that due to one or more of the parameters failing to meet the
criteria, then the performance guarantee provided by the Contractor for the first two years of the Defects Notification Period would
not be released but would be retained until the end of the Defects Notification Period, or until the relevant remedial work has been

successfully completed, whichever is the sooner. Alternatively, the Contractor shall have the option of rectifying the defects in
return for the release of the first of the performance guarantees provided by the Contractor.
Should the Engineer, in consultation with the Employer, confirm that immediate remedial work is required in respect of one or more
of the parameters then the Contractor shall immediately propose a solution to rectify the problem in accordance with Clause
D.7.1.8. The Engineer’s approval shall be obtained prior to the Contractors carrying our any remedial work. Notwithstanding the
approval by the Engineer of the remedial work, the Contractor shall remain fully liable for the performance of his proposed remedial
action(s) measured in terms of the specified performance parameter. Once the remedial work has been successfully completed,
then the Engineer will issue a report to the Contractor recording the remedial work done and confirming the results of the
assessment.
The first of the performance guarantees provided by the Contractor, would then be released.
(iii) Assessment after year six (6) of the Defect Notification Period
Should all parameters meet the full Acceptance Criteria, then the Engineer shall issue a report to the Contractor confirming the
results of the assessment and confirming that the first six years of the Defect Notification Period have been successfully completed.
The Employer will also release the second of the performance guarantees provided by the Contractor.
Should one or more of the parameter fail to meet the full Acceptance Criteria, then the Engineer, in consultation with the Employer,
shall decide whether or not the immediate remedial work will be required to be carried out at that stage. The Engineer will issue a
report to the Contractor confirming the results of the assessment.
Should the Engineer, after consultation with the Employer, confirm that no immediate remedial work is required at that stage, then
the performance guarantee provided by the Contractor for the first two years of the Defect Notification Period (if not previously
released) as well as that provided for the first six years of the defects Notification Period, would not be released but would be
retained until the end of the defects Notification Period, or until the relevant remedial work has been successfully completed,
whichever is the sooner. Alternatively, the Contractor shall have the option of rectifying the defects in return for the release of the
first of the performance guarantees provided by the Contractor (if not previously released), as well as of the second of the
performance guarantees provided by the Contractor.
Should the Engineer, in consultation with the Employer, confirm that immediate remedial is required in respect of one or more of
the parameters, then the Contractor shall immediately propose a solution to rectify the problem(s) in accordance with Section D7.1.
The Engineer’s approval shall be obtained prior to the Contractor’s carrying out any remedial work. Notwithstanding the approval
by the Engineer of the remedial work, the Contractor shall remain fully liable for the performance of his proposed action(s)
measured in terms of the specified performance parameters. Once the remedial work has been successfully completed, then the
Engineer will issue a report to the Contractor recording the remedial work done and confirming the results of the assessment.
The first of the performance guarantees provided by the Contractor (if not previously released) and the second performance
guarantee, would then be released.
(iv) Assessment after year eight (8) of the Defects Notification Period
Should all parameters meet the full Acceptance Criteria, then the Engineer shall issue a First Approval Certificate in terms relevant
Conditions of Contract for Construction, confirming the results of the assessment and confirming that the entire eight-year Defects
Notification Period has been successfully completed. The contract shall then be complete and the Contractor shall then have no
further liability for the performance of the PPGS portion of the work. The Employer shall release all outstanding performance
guarantees provided by the Contractor for the entire Defects Notification Period.
Should one or more parameters fail to meet the full Acceptance Criteria then the Engineer, in consultation with the Employer, shall
decide whether or not immediate remedial work will be required to be carried out at that stage. The Engineer will issue a report to
the Contractor confirming the results of the assessment. The first and second performance guarantee provided by the Contractor,
if not previously released would now be released. The final performance guarantee would not be released but would be redeemed
by the Employer, with an amount of money (to be agreed with the Contractor as a fair value of any future remedial work, and with
the balance being released to the Contractor. The Contract shall then be complete and the Engineer shall issue the Final Approval
Certificate in terms of the Conditions of Contract. The Contractor shall then have no further liability for the performance of the
PPGS portion of the work, except for latent defects which may be identified.
Alternatively the Contractor shall have the option of rectifying the defects in return for the release of the full final performance
guarantee for the Defects Notification Period.
Should the Engineer, in consultation with the Employer, confirm that immediate remedial work is required in respect of one or more
of the parameters, then the Contractor shall immediately propose a solution to rectify the problem in accordance with the contract.
The Engineer’s approval shall be obtained prior to the Contractors carrying out any remedial work. Once the remedial work has
been successfully completed, then the Engineer will issue a report to the Contractor confirming the results of the final assessment.
Should all parameters fall within the full acceptance category, then all outstanding performance guarantees in the possession of
the Employer shall be released. The contract shall then have no further liability for the performance of the PPGS portion of the
work, except for latent defects which may be identified.
(v) Assessment at any time during the Defects Notification Period
The Employer or his agent shall be entitled to carry out an assessment for the work at any time during the Defects Notification
Period. Should any parameter fall into the remedial work required category, the Employer or his agent shall inform the Contractor
who shall immediately propose a solution to rectify the problem, and obtain the Employer’s or his agents approval and rectify the
problem in accordance with the approved method.
(vi) Data processing
Data obtained from field measurements pertaining to the condition of the joint seals shall be processed to produce results in the
manner presented in Table D7.1.8-1:

Table D7.1.8-1: Data processing
Item Specification
Type of measure Linear Metre (m) (tape measure)
Segment of length 200 m*
Method of assessment of data The ratio of the damaged seal to the total length of seal inspected for the
various types of distress measured in metres and expressed as a percentage.
Longitudinal and transverse joints to be measured separately
* This length can be measured over any 200 m section of carriageway and need not commence directly adjacent to the
termination of an abutting section, provided that no two sections shall overlap with one another
D7.1.8.4 Acceptance criteria

The measured defective joints shall meet with the acceptance criteria listed in Table D7.1.8-2:
Table D7.1.8-2: Acceptance criteria
Time after Maximum permissible distress length calculated (percentage %) of segment of transvers or longitudinal
commencement of joint for the various types of distress
the PPG period
(yrs)
Adhesion Cohesion Extrusion Weed Deformation

Growth
L T L T L T L+T L T
2 0 0 0 0 0 0 0 0 0
4 2 2.5 2 2.5 0 0 0 0 0
6 4 5 4 5 2 2.5 1 2 2.5
8 12 15 12 15 8 10 2 4 5
L = Longitudinal weakened plane joint T = Transverse contraction joint
In the event of the types of distress listed in Table D7.1.8-2 occurring simultaneously, then the maximum permissible distress values (calculated
by the summation of the percentage listed in Table D7.1.8-2 for the specified times after opening the concrete pavement to traffic shall meet with
the criteria listed in Table D7.1.8-3.
Table D7.1.8-3: Acceptance criteria

Maximum permissible distress for all the types of distress
Time after commencement of the PPG period (years)
listed in Table G1008/1
2 0%
4 5%
6 20 %
8 30 %
D7.1.8.5 Procedures to be adopted in the event of failure during the guarantee period
Where failures have occurred relating to the performance of the sealant under traffic or any other reason due to workmanship or materials used,
the Contractor shall at his own expense, rectify all segments in which such defects occur which exceeds the permissible criteria as indicated in
Table D7.1.8-2 as to bring the number the number of defects within the permissible limits. Actual repairs required shall be agreed by the panel.
Repair works shall be carried out at any time when required during the Guarantee Period, but at least during 2, 4, 6 and 8 as specified. During
years 2, 4, 6 and 8 repair works shall be carried out within a reasonable time after the specified inspections as agreed with the Employer and
these repair works will not be subject to a lane rental. Where repair works are required before the inspection in year 2, a lane rental charge shall
be applicable as stated in the Contract Data. The lane rental fee units shall be per lane per hour. No lane rental charge is applicable after the
inspection in year 2.
In the event of the Contractor failing to undertake the required steps to rectify/reinstate the defects to conform with the specified requirements, the
Employer reserves the right to withhold payment of any monies which are payable to the Contractor or which may become payable under the
contract, or should no such monies be owing, to call in the guarantee issued under the PPGS.
Furthermore, the Employer shall employ all such powers vested in him in terms of the General Conditions of Contract to uphold and enforce the
requirements specified herein related to the extended performance guarantee.
Should an alternative tender or contract guarantee period be accepted, the repair programme shall be as per the accepted alternative.
At the end of the Guarantee Period, and when the applicable maintenance certificate has been issued, all repair and maintenance responsibilities
shall become the responsibility of the Employer, except for latent defects which may arise after the end of the product performance guarantee
period.

D7.1.8.6 Notification of remedial work
The Employer or his agent shall notify the Contractor in writing of any remedial work or repairs required to the liquid sealant or accepted alternative
seal in terms of the product performance guarantee. Such notification shall take place at any time during the guarantee period, but at least after
year 2, 4, 6 and 8 such intervals as may be defined in an alternative tender.
The Contractor shall commence with the remedial work within thirty (30) days from the date on which he site is handed to him by an order in
writing from the Employer or his agent after the submission of a programme within fourteen (14) days from the date of the order.
D7.1.8.7 Remedial work

All remedial work or repairs to the liquid sealant or accepted alternative seal shall comply with the following requirements:
a) The Contractor shall at his own cost supply, erect and maintain the necessary temporary traffic control signs in accordance with the
requirements contained in Section A1.5 of Chapter 1, the drawings, and the latest edition of the South African Road Traffic Signs Manual.
Any future amendments to the aforementioned manual shall also be complied with.
b) The Contractor shall also, at his own cost, repair/reinstate such items as road studs, road marking etc. should these be damaged or influenced
by the required remedial work.
c) The only permissible types if liquid sealant material used for repairing the joints on this contract during the PPG Period shall be as follows:
• The product initially accepted to complete the project
• Any new or alternative product specifically accepted by the Employer
The costs incurred by the Employer for the repair and monitoring required in terms of the PPGS shall be deemed to be covered by the lump sum
allowed for in item C7.1.2.
D7.1.8.8 Alternative materials and design

The tender is afforded the opportunity to allow for alternative materials and specifications for work related to the product performance guarantee
system other than that allowed for in the contract documents.
Such alternatives shall however be identified at tender stage.
Full details relating to alternative tenders such as field measurements, acceptance criteria and proposed remedial work shall be submitted in a
manner similar to that prescribed in Clause D7.1.8.4
Alternative materials, properties or remedial measures proposed by the Contractor shall be to the acceptance of the Employer or his designated
representatives.
D7.1.8.9 Work on behalf of Employer

The Employer reserves the right during the periods in which remedial work is being undertaken in terms of the PPGS to order in writing additional
remedial work relating specifically to repairs to the joints sealed under the contract. Payment for such additional work shall be classed as “day
works” (costs plus 15 %) and the Contractor shall be compensated in accordance with relevant Conditions of Contract for Construction.

7.2 REPAIR TO EXISTING JOINTS AND UNCONTROLLED CRACKS
IN CONCRETE PAVEMENTS
CONTENTS
A7.2.1 SCOPE
A7.2.2 DEFINITIONS
A7.2.3 GENERAL
A7.2.5 MATERIALS
A7.2.8 WORKMANSHIP

A7.2 REPAIR TO EXISTING JOINTS AND UNCONTROLLED CRACKS IN

CONCRETE PAVEMENTS
A7.2.1 SCOPE
This Section covers work related to the repair of pavements across isolated uncontrolled cracks as well as repair of existing joints in concrete
pavements in the following instances:
- Repair of joints as well as uncontrolled cracking as part of the periodic maintenance/repair of existing pavements which includes repair to the
adjacent concrete. It may also require the retro-fitting of tie-bars and/or dowel bars in order to provide load transfer capacity over the crack or
joint as identified. This instance the area of repair shall be limited to only a portion of a panel adjacent to a joint, but may also traverse an existing
joint into a portion of an adjacent panel. In JCP pavements where the area covers a total existing panel area, the repairs shall be carried out in
conformance to the requirements specified in Section 7.3 as relevant.
A7.2.2 DEFINITIONS
Concrete Pavement Types - as defined in Clause A6.1.2 of Chapter 6.
Joint types - weakened-plane joints including transverse contraction, longitudinal hinge, expansion and transverse construction joints as indicated on
the Drawings.
Uncontrolled Cracking - as defined in TMH 9: Part C - Standard Visual Assessment Manual for Rigid Pavements.
A7.2.3 GENERAL
A7.2.3.1 General Requirements
Notwithstanding any specific requirements as prescribed in this Chapter, all work done shall be in conformance with all generally accepted good
practice recommendations as published in relevant industry guidelines to ensure adequate performance of the finished work. The Contractor shall
submit a method statement setting out the methodology he intends utilising for all operations envisaged to ensure conformance to all the specified
final requirements which shall be subject to the approval of the Engineer.

The weather limitations stated in Clause A6.1.3 of Chapter 6 shall also be applicable in this instance.

The Contractor shall design the concrete mix to comply with all the flexural strength and compressive strength requirements as specified in Clause
A6.1.4.2 of Chapter 6, with the exception that a rapid hardening CEM 52,5 R as specified in SANS EN 197-1, shall be incorporated to permit trafficking
within the prescribed period. Additional admixtures in the form of accelerators may be included however the dosage thereof shall be limited to 2 % of
the mass of the cement. The characteristics of the mix shall be such that the concrete can be placed, consolidated and finished within the delivery
and time constraints associated with the method statement as approved.
All mix designs shall be compiled by an approved concrete testing laboratory and approved by the Engineer.
A7.2.5 MATERIALS
A7.2.5.1 Aggregates
The aggregates incorporated in the replacement concrete shall comply with all the requirements as prescribed in Clause A6.1.5 of Chapter 6. The
Nominal Maximum Size of the aggregate shall be appropriate to the thickness of concrete to be placed and the placing and finishing methodology
to be used.
A7.2.5.2 Water
The requirements for water incorporated into the concrete mix shall be as specified in Clause A6.1.5 of Chapter 6.
A7.2.5.3 Cement
A high early strength cement shall be used for all full depth repairs. The accelerated strength shall be gained by using CEM class 52,5 R in
conjunction with an accelerator if required, but only if approved.
A7.2.5.4 Epoxy and repair products

The following repair and adhesive products to be utilised where specified shall appropriate for the intended purpose and shall be accepted by the
Engineer:
- A semi-fluid epoxy adhesive paste for the bonding of new concrete to existing concrete (wet to dry).
- A polyamide cured thixotropic epoxy adhesive paste for bonding tie bars to existing concrete and small epoxy repairs
- High strength concrete for partial depth repairs, filling tie bar and dowel slots as well as grout holes
- An epoxy for filling saw cuts
- A cementitious non-shrink grout for filling of wide joints
- A self-levelling pourable epoxy grout for use in cross stitching
- A low viscosity pourable epoxy for use in crack injection
The use of epoxy grout to repair spalling along transverse or longitudinal joints shall not be permitted. Spalled joints which are not eliminated by
the simultaneous repair of cracks in the close vicinity of the joints, shall be repaired by one of the types of treatment, specified hereinafter and as
shown on the drawings.
A7.2.5.5 Bond breaking products

A bond breaking product as shown on the drawings shall be applied to existing concrete faces where movement is to take place before the casting
of new concrete against it. The bond breaking product to be used shall be approved by the Engineer or alternatively, Contractor’s PVA paint or
similar approved material applied at a nominal rate of 0,25 /m².
A7.2.5.6 Tie bars, dowels, continuous reinforcing steel and steel mesh
The dimensions of any steel products shall be as specified in the Contract Documentation. The requirements for any steel shall be a specified in
Clause A6.1.5 of Chapter 6 as relevant.

work within the specified properties and construction tolerances.
The Contractor shall prepare the list of construction equipment required for the type and extent of repair for the specific project. The following
• Pedestrian and small ride-on roller,
• Vibratory plate compactor,
• Mobile compressor with matched paving breakers,
• Mechanical saw and hand tools,

• Drilling equipment,
• Hand-operated compactor,
• Mobile concrete mixer,
• Poker vibrators
• Vibrating levelling screeds/beams
• Any other tools and equipment necessary to complete the work in accordance with all the specified requirements

A7.2.7.1 Repairing joints and cracks
The use of epoxy grout to repair spalling along transverse or longitudinal joints shall not be permitted. Spalled joints which are not eliminated by
the simultaneous repair of cracks in the close vicinity of the joints, shall be repaired by one of the types of treatment, specified hereinafter and as
Wherever joints or cracks in the concrete pavement are formed or repaired, these shall be thoroughly cleaned of debris to the satisfaction of the
Engineer by means of high-pressure water jetting followed by high-pressure, oil-free air jetting to finally clean and dry the joints and/or cracks
before the installation of the cold-poured liquid sealant.
The following types of repair treatment shall be undertaken on existing joints/ cracks in the concrete pavement.
a) Type R1 Treatment: (Bevelling of spalled edges and resealing)
This treatment shall apply to joints spalled to degrees of medium and high severity as defined in TMH 9. Existing seals shall be removed and the
joints reamed out to produce clean-cut surfaces as described in Clause A7.1.7.1 above. The edges of the joints shall then be bevelled by means
of a mechanical device to dimensions of 10 mm, 15 mm or 20 mm (dependant on the depth of the spall) at a 45° angle before the installation of
the liquid sealant as described in Clause A7.1.7.1.
b) Type R2 Treatment: (Routing and bevelling of active cracks)
This treatment shall be applicable where identified active transverse or longitudinal cracks are to be treated without the breaking up of the concrete
slabs or portions thereof. This treatment shall entail the routing of cracks to the specified width and depth ratio as indicated on the drawings.
Back-up material shall be placed at the bottom of the routed slot and the remainder of the slot then be filled with a cold-poured liquid sealant to
the requirements and tolerances as prescribed in Clause A7.1.7.1. The routing and bevelling shall be executed in such a way that the actual crack
is always visible in the middle third of the width of the routed slot. This treatment may also be applicable to severely spalled transverse construction
joints.
c) Type R3 Treatment: (Routing and bevelling of non- active cracks)
This treatment is similar to treatment type R1 above except that the routing shall be executed to a constant depth and width of 15 mm x 15 mm.
The joint reservoir shall then be filled with a cold-poured liquid sealant. This treatment shall apply to smaller cracks or transverse construction
joints which show a high degree of spalling.
d) Type R4 Treatment: (Bevelling of forward slabs where faulting has occurred)
This treatment applies at transverse joints where the approach slab is 5,0 mm or more higher than the leave slab and entails the removal of the
existing seal, the bevelling of the higher edge (approach slab) and installing the new liquid sealant as prescribed in Clause A7.1.7.1.
e) Type R5 Treatment: (Cross-stitching)
This treatment shall apply to longitudinal joints and cracks and shall be used to maintain load transfer and to provide added strength by preventing
further movement of the joints/cracks.
Cross-stitching shall be carried out on active cracks before the application of a liquid sealant but after sub-sealing / slab-jacking if applicable.
Longitudinal cracks which have assumed the role of an adjacent longitudinal joint (i.e. where movement takes place) shall not be cross-stitched.
This operation involves the cutting of slots into the concrete pavement measuring ±1 000 mm x 50 mm x 175 mm using the smallest saw blade
diameter possible. The slots shall be cut equidistant on either side of the crack and at right-angles to the longitudinal axis of the pavement. The
slots shall be cleaned by means of water jetting and oil-free compressed air and a 16mm diameter reinforcing bar 760 mm long inserted in the
bottom of the slot.
The bar shall then be covered with a self-levelling pourable epoxy grout followed by a layer of 7,1 mm crushed stone. The remainder of the slot
is filled with a primer if specified by the manufacturer and followed with the provision of a high strength concrete Class 50/7 and finished-off level
with the pavement surface. Excess material is removed and the surface is left in a clean condition.
A minimum period of 3 days shall lapse between the placing of the high strength concrete and the opening of the road to traffic. Any excess
material resulting after the setting of the high strength concrete shall be removed to ensure the slot is finished to the same level as the adjacent
concrete.
f) Type R6 Treatment: (Crack injection)
Crack injection treatment shall be used for the reinstatement of slab integrity on low-severity inactive longitudinal and transverse cracks. The
crack shall be reamed out to a width and depth as indicated by the Engineer. Maximum width shall not exceed 12 mm and the maximum depth
shall not to exceed 42 mm.
The reamed-out crack is then cleaned with a high pressure water jet, followed by the use of oil-free compressed air to remove any residual
dirt. The surfaces shall be clean and dry before a low viscosity pourable epoxy is used under the manufacturer’s recommendations to fill the

crack. The epoxy shall be slowly gravity fed into the reservoir. Sufficient time is to elapse before the crack is topped up with resin to a final level
not exceeding the bottom of the reservoir.
The resin should be allowed to cure for 24 hours before joint-sealing can take place as described in Clause A7.1.7.1. The repaired section can
then be opened up to traffic after 3 days.
g) Type R7 Treatment: (Restoration of load transfer at transverse contraction joints)
This method of treatment is required at transverse joints where load transfer between adjacent slabs has deteriorated and resulted in pumping,
faulting, corner breaks and spalling.
This work shall involve the installation of 32 mm diameter dowels placed at mid-depth in the concrete pavement by means of cutting slots 640 mm
in length, 90 mm wide and 175 mm deep in the wheel path and across the existing transverse contraction joint. The sliding end of the dowels
shall be treated with a bond-breaking compound to prevent the concrete from adhering to it. The slots shall be cleaned by means of water jetting
and oil-free compressed air. Dowels fitted with end caps shall be inserted parallel to the longitudinal axis of the road and shall be placed on
supports of non-shrink grout. The slots shall then be filled with a high strength concrete Class 50/7 and finished flush with the existing concrete
pavement surface.
Excess material shall be removed and the surface left in a clean condition. The reinstatement of the transverse joint shall be undertaken in
accordance with Clause A7.1.7.1.
h) R8 Treatment: (Forming and sealing of joints between asphalt surfacing and concrete pavements)
This method entails the saw cutting of a slot 50 mm deep in the existing asphalt surfacing directly adjacent to the concrete pavement, the cleaning
of the joint reservoir and re-sealing of the joint with back-up material and a liquid sealant. Where excessive damage of the existing asphalt has
taken place at the contact line between the asphalt and the liquid seal, the asphalt shall be removed to a width of 100 mm or 150 mm and replaced
with continuously graded asphalt. The new seal shall then be installed as described in the first sentence of this paragraph.
A7.2.7.2 Repairing joints and cracks by full-depth removal of concrete adjacent to the crack or joint
a) Transverse crack and joint repairs by full depth removal of existing adjacent concrete and incorporating the following
treatments:
(i) Type T1 Treatment
This treatment applies to active transverse cracks situated approximately in the middle third of a slab or series of transverse slabs.
The existing concrete on either side of the crack is to be broken up and removed after two parallel saw cuts are made at positions
indicated by the Engineer. Before the new concrete is replaced, tie bars are to be installed along one of the existing transverse
concrete faces by means of drilling horizontal holes in the existing concrete and fixing tie bars with an epoxy adhesive paste. The
vertical side of the existing concrete face with tiebars is then treated with a wet-to-dry epoxy adhesive. The other face is treated
with a bondbreaker. The concrete and mesh are placed. New concrete shall be rounded and existing concrete mechanically
bevelled along the line of contact. The line of contact between existing and new concrete which is not tied shall be sawn in one
operation to a specified width and depth and the installation of a back-up material and a liquid sealant.
(ii) Type T2 Treatment
This treatment applies to the repair of transverse cracks in close proximity to transverse joints where the one limit of the concrete
repair area coincides with an existing transverse joint. A saw cut parallel to the joint encompasing the crack is made at a position
indicated by the Engineer. The existing concrete on either side of the crack is to be broken up and removed. Before the new
concrete is replaced, tie bars are to be installed along the newly cut face opposite the joint face by means of drilling horizontal
holes in the existing concrete and fixing tie bars with an epoxy adhesive paste. The vertical side of the concrete face with tiebars
is then treated with a wet-to-dry epoxy adhesive. The other face is treated with a bondbreaker. The concrete and mesh are placed.
New concrete shall be rounded and existing concrete mechanically bevelled along the line of contact. A sawcut is made along the
same line of the existing transverse joint on the contact line of existing and new concrete in one operation to a specified depth and
width and installation of a back-up material and a new liquid sealant.
(iii) Type T3 Treatment
This treatment applies where existing concrete is removed on either side of an existing transverse joint due to an active transverse
crack crossing over the existing joint. The existing concrete on either side of the crack is to be broken up and removed after two
parallel saw cuts are made at positions indicated by the Engineer encompassing the extent of the crack. Before the new concrete
is replaced, tie bars are to be installed along both of the existing transverse concrete faces by means of drilling horizontal holes in
the existing concrete and fixing tie bars with an epoxy adhesive paste. The vertical sides of the existing concrete faces with tiebars
are then treated with a wet-to-dry epoxy adhesive. The concrete and mesh are placed. The sawing of the joint at the location and
line of the original joint is performed in two operations consisting of an early 3,0 mm wide saw cut followed by the reaming of the
joint to a minimum width of 6,0 mm and depth of 35 mm and the installation of a back-up material and a liquid sealant.
(iv) Type T4 Treatment
This treatment is identical to type T3 treatment but applies only where the concrete is on either side of the joint line in separate
operations. The new concrete on either side of the transverse joint is placed in two operations with dowel bars treated with an
approved bond breaking compound as shown on the drawings and installed across the joint during the casting of the first portion
of concrete. Before the second portion of concrete is cast the vertical surface of the newly cast concrete shall be treated with a
bond breaking agent. The transverse joint is then sawn in two operations and followed with the installation of a back-up material
and liquid sealant.
(v) Type T5 Treatment
This type of treatment is similar to Type T2 treatment but applies when small portions of concrete slabs are removed and replaced
due to corner breaks, short cracks or similar defects. The treatment entails the drilling of horizontal holes into the existing concrete,
the application of an epoxy adhesive and the installation of a minimum of 3 tie bars before the placing of new concrete. Due to the
small horizontal dimensions of the repair area the normal spacing of tie bars as specified will have to be adjusted to ensure that a
minimum of three tie bars are installed. Wet-to-dry epoxy adhesive shall be applied to the surfaces where tie bars are installed
and a bond breaking agent along the vertical face of existing concrete at the joint where movement is to take place. A sawcut is

made along the same line of the existing transverse joint on the contact line of existing and new concrete in one operation to a
specified depth and width and installation of a back-up material and a new liquid sealant.
b) Longitudinal crack and joint repairs by full depth removal of existing concrete and incorporating the following treatments:
(i) Type L1 Treatment
This treatment applies to active longitudinal cracks situated approximately in the middle third of a slab or series of longitudinal
slabs. The existing concrete on either side of the crack is to be broken up and removed after two parallel saw cuts are made at
positions indicated by the Engineer. Before the new concrete is replaced, tie bars are to be installed along both of the existing
transverse concrete faces by means of drilling horizontal holes in the existing concrete and fixing tie bars with an epoxy adhesive
paste. The vertical sides of the existing concrete faces are then treated with a wet-to-dry epoxy adhesive. New concrete and
mesh shall be placed. New concrete shall be rounded and existing concrete mechanically bevelled along the line of contact.
(ii) Type L2 Treatment
This treatment applies to the repair of longitudinal cracks in close proximity to longitudinal joints where the one limit of the concrete
repair area coincides with an existing longitudinal joint. A saw cut parallel to the joint encompasing the crack is made at a position
indicated by the Engineer. The existing concrete on either side of the crack is to be broken up and removed. Before the new
concrete is replaced, tie bars are to be installed along the newly cut face opposite the existing joint face by means of drilling
horizontal holes in the existing concrete and fixing tie bars with an epoxy adhesive paste. Prior to placing concrete this face is to
be treated with a wet-to-dry epoxy The existing tiebars in the longitudinal joint are to be cleaned and straightened with the
installation of new tie bars if necessary and a bondbreaker is applied to this face. New concrete and mesh shall be placed. New
concrete shall be rounded and existing concrete mechanically bevelled along the line of contact. A sawcut is made along the same
line of the existing longitudinal joint on the contact line of existing and new concrete in one operation to a specified depth and width
and installation of a back-up material and a new liquid sealant.
(iii) Type L3 Treatment
This treatment applies where existing concrete is removed on either side of an existing longitudinal joint due to an active longitudinal
crack crossing over the existing joint. The existing concrete on either side of the crack is to be broken up and removed after two
parallel saw cuts are made at positions indicated by the Engineer encompassing the extent of the crack. Before the new concrete
is replaced, tie bars are to be installed along both of the existing longitudinal concrete faces by means of drilling horizontal holes
in the existing concrete and fixing tie bars with an epoxy adhesive paste. The vertical side of one of the existing concrete faces
with tiebars is then treated with a wet-to-dry epoxy adhesive. A longitudinal construction joint with tiebars is formed on the line of
the original joint with tiebars and mesh and concrete are placed on one side of the longitudinal joint. When the formwork is removed,
the face of the construction joints is treated with a bond breaking compound and the other face with a wet-to-dry dry epoxy. The
concrete and mesh are placed. The sawing of the joint at the location and line of the original joint is performed in two operations
consisting of an early 3,0 mm wide saw cut followed by the reaming of the joint to a minimum width of 6,0 mm and depth of 35 mm
and the installation of a back-up material and a liquid sealant.
(iv) Type L4 Treatment
This treatment is identical to treatment type L2 above but applies where small areas of concrete slabs are removed and replaced.
The treatment entails the drilling of horizontal holes into the existing concrete, the application of an epoxy adhesive and the
installation of a minimum of 3 tie bars. Wet-to-dry epoxy shall be applied to the vertical face where tie bars are installed, a bond
breaking agent shall be applied along the vertical face of the existing concrete at the joint, followed by rounding of the new concrete
and bevelling of existing concrete along the joint.
A7.2.7.3 Full depth repairs

Full depth repairs to isolated areas in the existing concrete panels shall be carried out at positions of both transverse and longitudinal cracking
where the degree of cracking has progressed to high severity and where there is evidence of surface spalling or faulting. Full depth repairs shall
also be required where spalling at joints or surface “pop-outs” extend beyond a depth greater than 75 mm from the surface.
The positions and minimum dimensions of the various types of repair sections, together with the type of joint preparation required, shall be as
indicated in the Contract Documentation.
Full depth repair work shall include:
- saw cutting around the perimeter of the repair sections,
- breaking up and removal of the concrete paving within the repair section,
- preparation of surfaces including repairs to subbase
- application of bond-breaker or wet to dry epoxy to faces,
- drilling and installation of tie-bars, dowels
- reinstatements of continuous reinforcing where it has been severed,
- placing and finishing of new concrete.
The nature of full depth repairs therefore is such that all identified defective concrete pavement within panels shall be repaired.
a) Removal of existing concrete
Prior to removal of concrete an initial full depth pilot saw cut shall be made 60 mm inside the boundary of the repair area and the concrete within
this initial saw cut shall be removed by either of two methods:
- the break up and clean out method or
- the lift out method
(i) The break up and clean out method may be carried out with a front end loader used together with a jackhammer. Breaking out may
be facilitated by additional intermediate saw cuts. The breaking operation shall proceed from the centre of the repair area towards the

boundary saw-cuts to eliminate damage to the adjoining slabs. Care shall also be taken with this method to avoid damage to the
subbase or to adjacent slabs.
(ii) The lift out method shall require lifting hooks to be attached to the slab and heavy lifting equipment to lift out larger areas. Alternatively
the slab may be sawed into smaller pieces so that they can be lifted out by a front end loader. Although this method is less liable to
damage the subbase and adjacent slabs, the Contractor is required to dispose of larger pieces of concrete.
Any repairs necessary to the subbase and adjacent slabs due to damage caused by the removal and breaking out of the concrete shall be to the
Contractor’s cost. If during the process of breaking out the concrete, the sawn edge of the remaining concrete is damaged beyond the repair
boundary, a further pilot cut parallel to the initial cut shall be sawn without any payment to the Contractor.
After removal of the bulk concrete a final saw cut, 50 mm deep, shall be made on the boundary of the repair area, 60 mm back from the pilot cut.
This remaining 60 mm vertical wedge shall be chopped out using hand tools or light pneumatic hammers with a maximum size of 14 kg in order
to provide a rough vertical face for aggregate interlock load transfer.
Where saw-cuts cross over each other at corners of repair areas, the saw-cuts extending beyond the boundary of the repair shall be filled with an
approved epoxy filler to the surface of the concrete pavement and the cost of such work shall be included under the rates for the repair. The
Contractor shall demonstrate by means of a trial that he is able to achieve a full depth penetration of the epoxy into the saw cuts extending beyond
the boundary of the repair.
Broken up concrete shall be removed from the road and road reserve and spoiled at locations arranged by the Contractor himself. No overhaul
will be payable for the removal of broken up concrete or any other materials resulting from the breaking up of concrete.
b) Preparation of repair area
After the existing concrete has been removed, the repair area shall be cleaned out using oil-free compressed air to remove all dust and loosened
concrete. Any partially loosened concrete that remains shall be removed by hand tools and wire brushing. The subbase shall then be examined
and any loose material which has been disturbed below the desired level of clean-out, shall be removed and repaired. The disturbed area shall
be neatly cut out to dimensions and depths as directed by the Engineer and the excavated cavity shall be cleaned of all loose debris. The
underlying pavement layers shall be compacted if required to the satisfaction of the Engineer and the cavity backfilled with a Class 10/20 concrete
and finished level with the adjacent subbase.
Where specified on the drawings, tie-bars shall be placed into the face of the existing slab. The equipment used for drilling tie-bars shall preferably
be the hydraulic percussion type and the drill shall not crack or spall the adjacent concrete. Tie bar holes shall be drilled at mid-depth of the slab,
and the diameter of the hole shall be a minimum of 4,0 mm, but not more than 6,0 mm, larger than the tie bar diameter as specified. A drill support
system, using the pavement surface or subbase as a reference, shall be required to assure correct alignment. Hand-held drills shall not be
permitted.
c) Installation of tie bars
After drilling, the tie-bar holes shall be cleaned out with compressed air prior to grouting in the tie-bars utilising an approved quick setting non-
shrink epoxy. The epoxy shall be injected to the rear of the hole and shall be dispersed along its full length to ensure that the bars are completely
covered and no voids exist. Lockset resin cartridge anchor systems may also be used. The bars shall be inserted with a twisting motion and
seated in place by tapping. Tie-bars shall be placed parallel to the surface and centre line of the pavement for transverse joints or perpendicular
to the centre line for longitudinal joints.
After placing of tie-bars the repair area shall again be cleaned out with oil free compressed air at a minimum pressure of 0,5N/mm2. The subbase
shall then be sprayed with a bitumen emulsion bond breaking agent and the vertical faces of existing paving coated with bond-breaker, or wet to
dry epoxy as indicated on the drawings. Wet to dry epoxy shall only be applied to a clean and dry concrete face, free of all dirt, loose material.
d) Installation of dowels
Dowels shall be positioned at the depth specified, measured from the surface level of the slab, within a tolerance of ± 10 mm. They shall be aligned
parallel to the finished surface of the slab, to the centreline of the carriageway and to each other within the following tolerances:
- All dowels in a joint shall be aligned within ± 2,0 mm per 300 mm length of bar.
- No individual dowel shall differ in alignment from an adjoining bar by more than 3,0 mm per 300 mm length of bar in either the horizontal or
vertical planes.
- All dowels in a joint shall be within ± 4,0 mm per 300 mm length of bar.
- No individual dowel shall differ in alignment from an adjoining bar by more than 6,0 mm per 300 mm length of bar in either the horizontal or
vertical planes.
- All dowels shall be equally positioned about the intended line of the joint within a tolerance of ± 25 mm.
e) Placing of Concrete
The time intervals between sawing, concrete removal, preparation and placing new concrete shall be as short as possible in order to eliminate or
reduce any potential for slab creep.
The subbase shall be damped down before the application of the wet to dry epoxy to the vertical concrete faces. The repair concrete shall be
placed when the wet to dry epoxy is tacky and within the time limit stipulated by the manufacturer of the epoxy. Where high early strength concrete
is required for early re-opening to traffic, the Contractor shall be required to mix the concrete as close as possible to the location of the repair area
in order to avoid premature setting of the concrete prior to placing. The concrete shall be placed and evenly spread up to the level of the mesh
reinforcing (were specified) as shown on the Drawings.
The mesh shall then be placed in position and the remainder of the concrete placed. The mesh shall be accurately cut to the dimensions required
and shall be discontinuous at joints. The concrete shall be compacted in place by means of an internal poker vibrator particularly near the edges
and corners. The surface shall be struck off at least twice with a screed flush with the existing pavement at the repair limits.
While the concrete is still plastic, the Contractor shall test the repair surface which shall be finished flush with the surrounding pavement to within
a tolerance of ± 3,0 mm between the surface of the repair and a straight edge placed on the adjacent concrete surface. Where two adjacent
panels are placed together across a transverse joint, transverse and longitudinal joints shall be formed by means of saw cutting as shown on the
Drawings. The initial saw-cut to the joint be carried out at the correct time and depth in order to avoid shrinkage cracks developing. Initial saw-

cutting time is dependent on temperature, curing etc. and should be carried out when the concrete strength is approximately 4 MPa and when
only slight ravelling of the joint occurs. The joint shall be sawed before the concrete cracks but before 24 hours after placement.
Only after the repair has been completed and gained adequate strength, shall the transverse joints be treated and re-sealed in accordance with
Clause A6.1.7 of Chapter 6 as relevant.
f) Texturing
Texturing shall comply with the requirements of Clause A6.1.7 of Chapter 6 and shall, as far as possible, match the existing texture. Hand operated
texturing devices shall be permitted with texturing commencing immediately after finishing with the burlap drag. The depth of texturing shall be
between 2,0 and 4,0 mm, and the spacing of the grooves shall not be less than 12 mm and not more than 25 mm apart in a random pattern. The
direction of the texturing shall be at right angles to the longitudinal axis of the pavement. The surface texture shall be applied and completed
before the concrete is so hard that the surface will be torn and coarse aggregate unduly loosened during texturing.
g) Curing
The repair shall be cured immediately after casting by the application of an approved resin based white pigmented curing compound as prescribed
in Clause A6.1.5 of Chapter 6. In order to assist accelerated curing for earlier reopening to traffic the repair shall be covered with black polythene
sheeting as soon as it can be applied without damaging the surface.
In hot and dry weather conditions, the repair shall first be covered with wet hessian before covering with the polythene sheet. During cold weather
or at night, the polythene sheeting shall be covered over with polystyrene sheeting or other insulation board as appropriate.
h) Trafficking
No traffic shall be permitted on any repaired areas until the concrete has achieved a strength of > 30 MPa and all the joints have been sealed.
A7.2.8 WORKMANSHIP
A7.2.8.1 General
The completed work shall exhibit no uncontrolled cracking.
A7.2.8.2 Level
When measured with a 3,0 m straight edge, the difference in level between the patch and the adjacent existing pavement shall be within ± 3,0
mm.
A7.2.8.3 Texture
The average depth of texture shall be between 2,0 and 4,0 mm as prescribed.

B7.2 REPAIR TO EXISTING JOINTS AND UNCONTROLLED CRACKS IN
CONCRETE PAVEMENTS
CONTENTS
B7.2.1 SCOPE
B7.2.2 DEFINITIONS
B7.2.3 GENERAL
B7.2.5 MATERIALS
B7.2.8 WORKMANSHIP
B7.2.1 SCOPE
B7.2.2 DEFINITIONS
B7.2.3 GENERAL

B7.2.5 MATERIALS


B7.2.8 WORKMANSHIP

C7.2 REPAIR TO EXISTING JOINTS AND UNCONTROLLED CRACKS IN
CONCRETE PAVEMENTS
(i) Preamble
None.
pay items.
km.
C7.2.1 Transverse and longitudinal crack and joint repairs incorporating the following
treatments
C7.2.1.1 Routing of active cracks (indicate width and depth) metre (m)
C7.2.1.2 Routing of non-active cracks (indicate width and depth) metre (m)
C7.2.1.3 Bevelling of one side of the crack (indicate dimension) metre (m)
C7.2.1.4 Bevelling of both sides of the crack (indicate dimension) metre (m)
C7.2.1.5 Saw cutting of cracks and joints in one operation (indicate depth and width) metre (m)
C7.2.1.6 Filling joint reservoir with cementitious non-shrink grout kilogram (kg)
C7.2.1.7 Installation of backing material in saw cut joints (to fit saw cut dimensions) metre (m)
C7.2.1.8 Installation of cold pour sealant litre (ℓ)
The unit of measurement of routing shall be the metre (m) of transverse, longitudinal or random cracks routed. Distinction shall be made between
different widths and depths of routing.
The unit of measurement for bevelling shall be the metre (m) of bevelling undertaken at longitudinal and transverse joints and cracks. Distinction
shall be made between different sizes of bevelling and for bevelling on one or both sides of joints/cracks.

The tendered rate for bevelling and routing shall include full compensation for providing the plant and equipment required and for cutting the
bevels and rout grooves to the required dimensions indicted on the drawings as well as for the cleaning of the routed crack/joint by means of high
pressure water jetting followed by oil free high pressure air jetting prior to the installation of the back-up material or sealant.
The tendered rate for the installation of the back-up material shall include full compensation for providing the labour and equipment required. The
tendered rate shall also include for the cleaning of the joint by means of high pressure water jetting followed by oil free high pressure air jetting
prior to the installation of the back-up material.
The unit of measurement of cold poured liquid sealant shall be the litre () of cold-poured liquid sealant applied to the joint reservoir. The tendered
rate for cold-poured liquid sealants shall include full compensation for the supply and delivery of the materials to the point of installation and the
installation of the sealant. The tendered rate shall also include for the supply and application of joint primer to the vertical faces of the joint groove.
C7.2.2 Grouting of cracks metre (m)
The unit of measurement shall be the linear metre of crack grouted irrespective of width, in accordance with the Specifications, and the quantity
shall be the summation of individual lengths grouted measured along the line of the crack. The tendered rate shall include for the supply and
mixing of the grout, pouring it into the crack, repeating the process as often as is necessary to fill the crack, and for subsequent cleaning of the
slot and pavement surface of all grout.
C7.2.3 Cross-stitching of longitudinal and transverse joints and cracks
C7.2.3.1 Saw cutting of slots in concrete pavement (indicate dimensions) number (No)
C7.2.3.2 Application of wet-to-dry epoxy to vertical faces and top of existing concrete litre (ℓ)
C7.2.3.3 Installation of 16 mm diameter deformed tie-bar (indicate length) including application of self- number (No)
levelling pourable epoxy grout and 7,1 mm aggregate.
C7.2.3.4 Filling of slot with high strength concrete Class 50/7,1 mm cubic metre (m³)
The tendered rate for cross-stitching by means of cutting slots shall include full compensation for the saw cutting slots in the concrete pavement,
excavating the concrete, cleaning of the slots by sand blasting followed by high pressure air jetting, and the removal of all waste material resulting
from this procedure.
The tendered rate for the installation of the tie bars shall include full compensation for supplying, cutting, placing, holding bars in position, the
application of self- levelling epoxy grout and for the 7,1 mm crushed stone aggregate placed on top of the epoxy grout.
The tendered rate for filling slots with a high strength concrete shall include full compensation for the placing of the high strength concrete, the
removal of any excess material to ensure that the slots are filled flush with the concrete surface and for the curing of the high strength concrete in
accordance with the manufacturer’s instructions as well as texturing the concrete by burlap drag.
C7.2.4 Restoration of load transfer at transverse contraction joints
C7.2.4.1 Saw cutting and preparation of slots in concrete pavement (indicate dimensions) number (No)
C7.2.4.2 Installation of new dowel bars as specified (indicate length and diameter) including number (No)
application of bond breaker on free end, end caps.
C7.2.4.3 Filling of slot with high strength concrete Class 50/7,1 mm number (No)
C7.2.5 Pre-treating existing dowels
C7.2.5.1 Free ends in existing concrete number (No)
C7.2.5.2 Free ends in new concrete number (No)
The unit of measurement shall be the number of bars treated.
C7.2.6.1 Burlap-dragged and grooved texture: square metre (m²)
C7.2.6.2 Curing
(a) Paving train constructed square metre (m²)
(i) Labour enhanced construction

and curing compound as specified. The quantity shall be calculated from the specified horizontal dimensions of the completed concrete surface. The
tendered rate for texturing shall include full compensation for providing the plant and equipment required and for applying the specified surface texture.
The unit of measurement for steel bars shall be the ton of reinforcing steel in place in accordance with the drawings or as authorized.
authorized.

D7.2 REPAIR TO EXISTING JOINTS AND UNCONTROLLED CRACKS IN
CONCRETE PAVEMENTS
CONTENTS
D7.2.1 SCOPE
D7.2.2 GENERAL

Where applicable, details shall be provided in the Contract Documentation.

7.3 REMOVAL AND REINSTATEMENT OF EXISTING CONCRETE
LAYERS
CONTENTS
A7.3.1 SCOPE
A7.3.2 DEFINITIONS
A7.3.3 GENERAL
A7.3.5 MATERIALS
A7.3.8 WORKMANSHIP

A7.3 REMOVAL AND REINSTATEMENT OF EXISTING CONCRETE LAYERS

A7.3.1 SCOPE
This Section covers work related the removal and replacement of concrete pavements in the following instance:
- Sections where the newly placed concrete layer as completed in accordance with Chapter 6: Concrete Layers has been rejected by the Engineer
as a result of poor construction, finishing or uncontrolled cracking. This work shall not be subject to any payment.
- Where isolated non-continuous panels, or part of a panel, require replacement as part of the periodic maintenance/repair of an existing pavement
as described in the Contract Documentation. This work shall be subject to payment in accordance with the specifications and rates at tendered
in Part C: Measurement and Payment of this Section A7.3.
Where concrete pavements have to be widened, or where long continuous sections of concrete pavement have to be replaced and the concrete can
be placed with pavers, the work shall be regarded, and be measured and paid for, as new work in accordance with the requirements of Chapter 6:
Concrete Layers, Part A or B as may be prescribed.
A7.3.2 DEFINITIONS
Jointed Concrete Pavement (Plain JCP) - concrete pavements that contain sufficient joints to control all expected natural cracks. All necessary
cracking occurs at joints and not elsewhere in the slab. However, there may be load transfer devices (e.g., dowel bars) at transverse joints and
deformed steel bars (e.g., tie bars) at longitudinal joints, which is not considered as reinforcement. There may be isolated reinforced panels
(usually in the form of welded steel mesh at approximately 0,1 %, or higher, of gross slab cross-sectional area).
Continuously Reinforced Concrete Pavement (CRCP) - concrete pavements that include continuous longitudinal reinforcement steel typically
between 0,50 and 0,70 % of the cross-sectional area of the pavement slab. They also typically include transverse reinforcing consisting of
individual bars placed at approximately 1,0 m intervals.
Aggregate - granular material of natural, manufactured or recycled origin used in the manufacture of cemented products to the specific grade/class
as defined in these specifications and the latest published version of SANS 1083, or as may be otherwise specifically specified in the Contract
Documentation:
- Course aggregate – all aggregate > 5,0 mm as further defined in the latest SANS 1083 specification for the specific class of aggregate and
nominal maximum aggregate size as required.
- Nominal maximum particle size (NMPS) – designated as one sieve size larger than the largest sieve to retain a minimum of 15 % of the
aggregate particles.
- Fine aggregate – all aggregate fractions ≤ 5,0 mm and which shall consist of clean material derived from crushing competent parent rock,
or naturally occurring sand conforming to SANS 1083 and any further specified requirements listed herein.
Cement - as defined in SANS 50197-1 for the various classes as listed.
Cement extenders - The following as defined in the relevant publications:
- Ground Granulated Blast Furnace Slag: As defined in SANS 55167-1

- Fly Ash: As defined in SANS 50450-1
- Silica Fume: As defined in SANS 53263-1
A7.3.3 GENERAL
A7.3.3.1 Quality Plan and Method Statement
Prior to commencing with any permanent works, the Contractor shall submit a Quality Plan, for acceptance by the Engineer, detailing a complete
method statement, together with all checks and hold points, relating to construction of the specified product.

The initial area where the existing concrete pavement is to be removed, substrate layers repaired where required, and new concrete placed and
finished, shall be regarded as a trial section. The intention is for the Contractor to demonstrate that the materials, material mix design and
construction methods to be used will ensure that the final product conforms to all the relevant requirements as specified. Any work not meeting
the requirements shall be removed and reinstated by the Contractor at no additional cost.
The Contractor may, unless advised of any deficiencies in the trial section, proceed with the construction of the pavement 5 days after the completion
proceed with the construction of the pavement 5 days after the satisfactory completion and acceptance of the second or any subsequent trial section.
Contractor to continue with any permanent work. The intention of this Clause is to avoid any experimentation by the Contractor on the permanent
work.
No additional payment shall be made for such deemed trial sections. Payment for accepted work shall be in accordance with the tendered rates
once approved by the Engineer.

a) Responsibility for protection
The Contractor shall be responsible for the quality and strength of the concrete placed and for its protection. Any concrete damaged by adverse
weather (e.g., any combination of high ambient temperature, low humidity, wind, rain and hail) shall be removed and replaced at the Contractor's
expense.
b) Protection against rain or hail
No concrete shall be placed during rainy weather. For the concrete to be properly protected against rain and hail before it has sufficiently hardened,
the Contractor shall have available at all times appropriate waterproof covers for protecting the surface of the unhardened concrete. When rain
appears to be imminent, all paving operations shall cease and the Contractor shall take the necessary steps to protect the unhardened concrete.
The Contractor shall be responsible for the repair of any damage to the concrete, texturing or the curing compound that may occur.
c) Cold-weather paving
All reasonable precautions shall be taken to prevent the temperature of the pavement concrete from falling below 5C during the first 48 hours
after casting. When prevailing temperatures are low, or when cold weather is forecast and there is a danger that the temperature of the freshly
constructed concrete pavement will fall below the prescribed limits the Contractor shall either cease all pavement operations, or he may be
permitted to proceed, provided that the Engineer is satisfied that adequate protective measures are available, and will be taken, to ensure that
the temperature of the pavement will be maintained above 5C for the period stated.
d) Hot-weather paving
When paving is done during hot weather and when the temperature of the fresh concrete can be expected to exceed 24C, the Contractor shall
implement appropriate precautionary measures to place the concrete at the coolest temperature practicable. Paving operations shall cease when
the concrete temperature as discharged at the paver exceeds 32C.
e) Hot and windy weather paving
Unless appropriate and adequate protection measures to the plastic concrete are provided, all production of concrete and paving operations shall
cease when the prevailing evaporation rate, as determined in accordance with the nomograph given in Section A20.1 of Chapter 20 exceeds 1,0
kg/m²/hr.
Where provision has been made in the Pricing Schedule for the establishment of a portable weather station to be located in the immediate vicinity
of the paving site and positioned at 1,0 m above the level of the pavement being constructed. During paving operations the Contractor shall
provide the Engineer with all the relevant data as recorded by the weather station.

A7.3.4.1 Concrete mixes
a) Lean-mix concrete layers
The lean mix concrete for use in the underlying subbase layer shall consist of 10 MPa concrete designed in accordance with the relevant requirements
listed in Chapter 13.

b) Concrete layers
The Contractor shall design the concrete mixes in accordance with all the requirements as listed in Clause A6.1.4 of Chapter 6 with the exception
that, where rapid strength gain is required to permit opening to traffic within any prescribed period, rapid hardening cements/accelerating admixtures
may be incorporated. The use of such shall however not absolve the Contractor from ensuring that the concrete can be delivered, placed, consolidated
and finished to the specified requirements and with no drying/plastic shrinkage cracking occurring.
The mix designs shall be undertaken by an approved laboratory.
A7.3.4.2 Hot mix asphalt

Where hot mix asphalt is to be used in the subbase layer beneath the concrete layer, the mix shall be designed by a competent laboratory according
to the design level 1A as defined and described in Sabita Manual 35: Design of hot Mix Asphalt. The asphalt mix shall be of the sand skeletal type as
defined and may be either continuously or semi-gap graded.
The mix properties shall conform to all the requirements listed for this mix type and design level, with the exception that additional binder shall be
added in order to achieve a Voids in Mix (VIM) value of < 1 % and a Voids Filled with Binder (VFB) value > 90 %.
A7.3.4.3 Stabilised layers

Where stabilised layers are to be used in the supporting layers, the stabilisation design shall conform to the relevant material requirements as
prescribed in Chapter 4 as well as the general requirements contained in TRH 13: Stabilisation.
A7.3.5 MATERIALS
A7.3.5.1 Concrete
All the relevant concrete and other material requirements, as prescribed in Clause A6.1.5 of Chapter 6, shall be applicable.
A7.3.5.2 Hot mix asphalt

All the relevant material requirements, as prescribed in Clause A9.1.5 of Chapter 9: Asphalt Layers, for the particular mix type shall be applicable.
The binder grade shall be 50/70 complying with SANS 4001 – BT1 or the equivalent Performance Grade class.
A7.3.5.3 Stabilised material

All the requirements as listed in Chapter 4 shall be applicable for the class of layer specified.
A7.3.5.4 Tie bars, dowel bars and reinforcing mesh

Tie bars, dowels and reinforcing mesh shall comply with the requirements of Clause A6.1.5 of Chapter 6, as relevant. The dimensions of each type
shall be as indicated in the Contract Documentation.

work within the specified properties and construction tolerances.
The Contractor shall prepare the list of construction equipment required for the type and extent of repair for the specific project. The following
• Pedestrian and small ride-on roller,
• Vibratory plate compactor,
• Mobile compressor with matched paving breakers,
• Mechanical saw and hand tools,
• Drilling equipment,
• Hand-operated compactor,
• Mobile concrete mixer,
• Poker vibrators
• Vibrating levelling screeds/beams
• Any other tools and equipment necessary to complete the work I accordance with all the specified requirements

A7.3.7.1 Removal of existing concrete
Where any section of the concrete pavement has to be removed, the whole panel between longitudinal and transverse joints shall be removed, unless
it is specified in the project specifications or ordered by the Engineer that only part of the panel be removed. In such cases the concrete shall be
removed either over the full length or over the full width of the panel between joints. Where the edge of the section to be removed coincides with an

existing joint, the edge shall be accurately demarcated in a straight line and sawn with an approved concrete saw to a depth of at least 50 mm before
the removal of the concrete may commence.
Existing concrete may be broken up by the sawing and lifting of panels, or by sawing the boundaries of the area to be removed and breaking up the
internal concrete by suitable equipment. The method of removal shall be approved by the Engineer, but strict control shall be exercised to ensure that
the adjacent concrete is not damaged in any way. The Contractor shall repair any damage to the adjacent concrete, at his own cost, in accordance
with the instructions of the Engineer. Any remedial work may involve the partial or complete replacement of the damaged panel should it be deemed
necessary by the Engineer.
Care shall be taken at existing joints to ensure that tie bars or dowels are not damaged or bent so as to render them useless. In the case of continuously
reinforced concrete, the concrete shall be removed in such a manner so as to preserve the continuity of the reinforcing steel in all directions. Any
discontinuity caused through removal of the concrete shall be reinstated in accordance with the Contract Documentation and approved
Broken-up concrete shall be removed to an approved spoil site.
A7.3.7.2 Preparing the underlying layer/s after concrete has been removed
a) Underlying layers remaining in place
Where the underlying layer does not have to be removed or reworked after the existing concrete pavement has been removed, it shall be prepared
as follows:
(i) Cemented layers
Where the layer consists of cemented material or cemented crushed stone in accordance with the classification of Chapter 4, and
unless otherwise instructed by the Engineer, its surface shall be swept clean and all loose, soft or poorly cemented material shall be
removed. A primer shall then be applied consisting of a stable spray grade emulsion complying with the requirements of SANS 4001
BT-3 cut back to 30 % net bitumen to result in a nominal net bitumen application rate of 0,4 l/m². No primer may be spilt onto the
existing concrete pavement.
After the primer has dried out sufficiently, the surface shall be tested for irregularities in all directions with a 3,0 m straight-edge. All
holes and depressions where the surface deviates by more than 25 mm from the bottom side of the 3,0 m straight-edge shall be filled
in with coarse slurry as specified in Chapter 10, with the exception that the void content in the micro surfacing shall be so designed as
to produce the lowest compacted void content as possible. The micro surfacing shall be thoroughly compacted with appropriate
compaction plant and finished flush with the surface of the layer. The levels of the layer shall be such that the concrete pavement
constructed on it will comply with all the tolerances applicable thereto.
Dependant on the rate of quantity required, the micro surfacing may either be batched in a purpose made slurry machine or in suitable
portable concrete mixers. The surface shall be fully cured and then thoroughly cleaned and dampened with water immediately before
the new concrete is placed.
(ii) Asphalt layers
The layer shall be cleaned and all damaged and loose sections removed. A bond coat consisting of a stable grade emulsion complying
with SANS 4001 BT- 3 cut back to 30 % net bitumen to result in a net bitumen application rate of 0,4 l/m² shall then be applied. No
bond coat may be spilt onto the existing concrete pavement.
The surface shall then be tested for irregularities in all directions with a 3,0 m straight-edge, and the surface may not deviate by more
than 25 mm from the bottom edge of the straight-edge at any point. Where the surface is too small for a 3,0 m straight-edge, a shorter
straight-edge shall be used. All holes and depressions where the surface deviates by more than 25 mm from the bottom side of the
straight-edge shall be filled in with coarse slurry as specified in Chapter 10, with the exception that the void content in the micro
surfacing shall be so designed as to produce the lowest compacted void content as possible. The micro surfacing shall be thoroughly
compacted with appropriate compaction plant and finished flush with the surface of the layer. The levels of the layer shall be such that
the concrete pavement constructed on it will comply with all the tolerances applicable thereto.
Where so instructed by the Engineer, a further coat consisting of 30 % stable-grade bitumen emulsion complying with SANS 4001 BT
shall be applied to the underlying layer immediately before the concrete is placed at a nominal net bitumen application rate of 0,4 l/m².
The emulsion shall be fully cured and the surface shall then be thoroughly cleaned immediately before the new concrete is placed.
(iii) Recompaction of existing underlying pavement layers
Where required, the Contractor shall break up and recompact existing pavement layers to the density specified in the Contract
Documentation. Particular attention shall be given, and appropriate equipment provided, to ensure compliance with the compaction
requirements in the corners of any excavation.
b) Removal of existing underlying pavement layers
Where existing underlying pavement layers are to be removed, the method, and associated equipment, shall be appropriate to the area of the
excavation, and be such to enable the particular layers to be removed without any damage to the surface of layer to remain in place, or any layers
adjacent to the excavation. The re-use of excavated material shall not be a requirement, except where it is specified in the Contract Documentation.
All excavated material shall be disposed of at an approved spoil/dump site.
A7.3.7.3 Reinstating underlying layers during rehabilitation work

Any underlying layer/s removed shall be replaced with layers as specified in the Contract Documentation. The requirements for each specific layer
type shall be as follows.
a) Gravel layers
The replacement gravel layers shall be as indicated in the Contract Documentation. The material properties and compaction requirements shall
conform to the specific class of gravel as defined in Chapters 4 and 5. Particular attention shall be given, and appropriate equipment provided, to
ensure compliance with the compaction requirements in the corners of any excavation.
b) Stabilised layers
The replacement stabilised layers shall be as indicated in the Contract Documentation. The material properties and compaction levels shall conform
to the relevant requirements as specified and defined in Chapters 4 and 5 for the specific class of gravel, including stabilisation and compaction

requirements. Particular attention shall be given, and appropriate equipment provided, to ensure compliance with the compaction requirements in the
corners of any excavation.
Mixing in of the stabilising agent shall not be done in-situ but in appropriate mixers off the adjacent pavement as appropriate for the volume of material
to be stabilised.
c) Lean mix concrete (minimum thickness of 100 mm)
Where the excavated subbase layer is to be reinstated with lean mix concrete, the concrete shall be mixed in appropriate batching plants or mobile
concrete mixes located off any adjacent pavement surface, and then transported, placed, consolidated and finished in accordance with the
requirements in Clause B6.1.7.3 of Chapter 6. Consolidation of the concrete shall be by means of appropriate poker vibrators.
d) Hot mixed asphalt
The asphalt shall be manufactured, delivered, placed and compacted within the temperature requirements as prescribed in Chapter 9: Asphalt Layers
for the particular mix approved. Particular attention shall be given, and appropriate equipment provided, to ensure compliance with the compaction
requirements in the corners of any excavation.
e) Micro surfacing
Micro surfacing (slurry) shall be designed, batched and placed in accordance with the relevant requirements contained in Chapter 10: Surface
Treatments.
A7.3.7.4 Reinstatement of tie bars, dowel bars continuous reinforcing and reinforcing mesh
a) Tie bars
(i) In new concrete
Tie bars installed across longitudinal hinge joints of panels consisting of new concrete shall be located at the spacing and depth as
indicated in the Contract Documentation. Treatment and installation shall be in accordance with Clause A6.1.7 of Chapter 6.
(ii) Between existing and new concrete
At longitudinal hinge joints between existing and new concrete, the tie bars extruding from the existing concrete after removal of the
concrete shall be cleaned and straightened and accurately aligned as specified. Existing tie bars that have been irreparably damaged
or destroyed as a result of poor workmanship by the Contractor during breaking up of the existing concrete, or by the sawing and lifting
out of the pavement method if so selected by the Contractor, shall be reinstated by the Contractor at no cost.
In such instances holes shall be drilled into the vertical face of the adjacent existing concrete slab at a spacing and depth equivalent
to that in the existing pavement, and shall be approved by the Engineer. The material requirements shall be as prescribed in Clause
A6.1.5 of Chapter 6, as relevant, and the dimensions of the bars shall be equivalent to those destroyed. The tie bars than then be fixed
into the existing concrete utilising an appropriate epoxy as approved by the Engineer and aligned prior to casting any adjacent new
concrete.
Where no tie bars exist, but are required, new tie bars shall be installed as specified above and shall be provided for, as relevant, in
Part C: Measurement and Payment.
Where no bars are required between the existing and new concrete but such bars do exist in the adjacent existing concrete, such bars
shall be cut off flush with the concrete edge.
b) Dowel bars
(i) In new concrete
Dowel bars installed across transverse contraction joints of new concrete shall be located at the spacing and depth as indicated in the
Contract Documentation. Treatment, installation and allowable tolerances shall be in accordance with Clause A6.1.7 of Chapter 6.
(ii) Between existing and new concrete
At transverse contraction joints, the existing dowels protruding from the face of the concrete exposed, after removal of the deficient
adjacent concrete, shall be cleaned, and where required, straightened to comply with the relevant tolerances prescribed. Where the
sliding end of any undamaged dowel bars occur in existing concrete, the dowel bar shall be extracted, cleaned, treated and then
replaced.
Where any existing dowel bars have been irreparably damaged or severed due to the Contractor’s method of breaking out the existing
concrete, any deficient dowel bars shall be cut off, and new dowel bars of similar dimensions installed at locations and spacing as
approved by the Engineer. No payment shall be applicable for any such associated costs. In such instances holes shall be drilled into
the vertical face of the adjacent existing concrete slab at a spacing and depth equivalent to that in the existing pavement and as
approved by the Engineer. The material requirements shall be as prescribed in Clause A6.1.5 of Chapter 6, as relevant, and the
dimensions of the bars shall be equivalent to those destroyed. The fixed end of the dowel bars than then be fixed into the existing
concrete utilising an appropriate epoxy as approved by the Engineer and aligned prior to casting any adjacent new concrete.
In such cases, no payment shall be applicable for such reinstatement.
Where the dowel bars have been previously damaged or severed, or where the saw and lift-off method has been prescribed in the
Contract Documentation, the dowel bars shall be reinstated in accordance with the drawings. Where no bars are required between
the existing and new concrete but such bars do occur in the existing concrete, such bars shall be cut off flush with the concrete edge.
In such cases payment shall be applicable in accordance with Part C: Measurement and Payment.
Before concrete is placed, all the bars shall be accurately aligned as indicated on the drawings and specified in Clause A6.1.8 of
Chapter 6. Where tie bars or dowels are shown on the drawings at joints between existing and new concrete, but no such bars occur
in the existing concrete, holes shall be drilled in the existing concrete and fresh bars placed and fixed as prescribed in the Contract
Documentation. In such cases, the dowels shall be placed with their sliding ends in the new concrete.

c) Continuous reinforcing steel
(i) In new concrete
Continuous reinforced steel shall be installed in the new concrete in accordance with the details as indicated in the Contract
Documentation. Installation and allowable tolerances shall be in accordance with Clauses A6.1.6 to 8 of Chapter 6.
(ii) In existing concrete
Where the continuous reinforcing steel in the existing CRCP pavement has been severed during excavation of the concrete by the
Contractor as a result of poor workmanship or the saw and lift-off method selected by the Contractor, he shall reinstate the steel by
means of splicing in accordance with drawings.
Where the reinforcing steel has been previously severed, or where the saw and lift-off method has been prescribed in the Contract
Documentation, the reinforcing steel stall be reinstated in accordance with the drawings.
d) Reinforcing steel mesh
(i) In new concrete
Reinforcing steel mesh shall be installed in the new concrete in accordance with the details as indicated in the Contract Documentation.
Installation and allowable tolerances shall be in accordance with Clauses A6.1.6 to 8 of Chapter 6.
(ii) In existing concrete
Where the reinforcing steel mesh in the existing pavement has been severed during excavation of the concrete by the Contractor as
a result of poor workmanship or the saw and lift-off method selected by the Contractor, he shall reinstate the steel by means of splicing
in accordance with drawings.
Where the reinforcing steel has been previously severed, or where the saw and lift-off method has been prescribed in the Contract
Documentation, the reinforcing steel stall be reinstated in accordance with the drawings.
A7.3.7.5 Replacing the concrete

Where new concrete is placed next to existing concrete, the edge of the existing pavement shall be properly cleaned and all bituminous and other
jointing material shall be removed.
Where various adjacent panels are constructed, the concrete in every alternate panel shall first be placed. The concrete in the rest of the panels may
be placed only after the concrete in the first panels has sufficiently hardened so that no damage will be done to the first panels during construction
activities. All formwork shall remain in position for at least 24 hours.
Before concrete is placed, the underlying surface or layer shall be prepared as specified.
Except where concrete is placed in continuous lengths exceeding 50 m, placing, compacting and finishing with hand equipment shall be carried out
as specified in Clause B6.1.7 of Chapter 6.
The concrete shall be placed, consolidated and finished in accordance with the requirements as prescribed in Clause B6.1.7 of Chapter 6. No traffic
shall be permitted on the concrete until the compressive strength has reached a minimum of 30 MPa and all the joints have been sealed.
A7.3.7.6 Forming of joints

Where relevant and indicated, all joints between the existing and new concrete shall be sawn after the new concrete has hardened sufficiently to
prevent spalling or other damage from occurring. The timing of such sawing will be dependent on the characteristic of the particular cement
incorporated in the concrete mix but shall be such as to prevent any uncontrolled shrinkage cracking occurring. The width and depth of the sawn
grooves shall comply with the requirements in the Contract Documentation.
All joints shall be formed and sealed as prescribed in Clause A6.1.7 of Chapter 6 and/or Section A7.1 as relevant. All joints shall be sealed before
opening to traffic.
A7.3.7.7 Initial texturing and curing

a) Texturing
After the concrete has been placed and finished the texture shall be formed as prescribed in Clause A6.1.7.3 of Chapter 6. The pattern and depth of
texturing shall be as close as possible to that existing on the adjacent existing concrete.
b) Curing
The curing compound shall be applied in accordance to the requirements prescribed in Clause A6.1.7.3 of Chapter 6 immediately after completing the
texturing.

A7.3.8 WORKMANSHIP
A7.3.8.1 General
The completed work shall exhibit no uncontrolled cracking.
A7.3.8.2 Level and Grade

The level tolerance on any portion of full depth fresh concrete cast between existing panels or portions thereof, shall be governed by the levels
on the adjacent edges of the existing concrete. Where the fresh concrete is a portion of an existing panel the level shall be checked by a 3,0 m
straight-edge placed across the existing concrete edges and the level of the fresh concrete shall not deviate by more than ± 3,0 mm from the line
of the straight-edge.
Where complete panels are replaced between existing joints, the longitudinal grade tolerance of each replaced panel shall be governed by the
longitudinal grade along the edge of adjacent concrete panels remaining in position. The concrete shall be finished flush with the adjacent panels
and the maximum deviation from the existing longitudinal grade shall not exceed ± 3,0 mm.
For thin bonded arris and surface repairs the fresh concrete shall be finished flush with the surrounding concrete to within a tolerance of ± 3,0
mm.
A7.3.8.3 Thickness
Where full depth panels or portions thereof, are replaced on top of the existing subbase layers, the nominal thickness of the concrete shall be
equal to the nominal thickness of the adjacent concrete pavement.
A7.3.8.4 Surface Regularity

Where single concrete panels or portions thereof are replaced between existing panels, no irregularity of more than 3,0 mm shall be measured
with a rolling straight-edge or a 3,0 mm long straight-edge laid along the centre line of the road.
A7.3.8.5 Testing frequency

For full-depth repairs the testing frequency for construction tolerances shall be as per the following:
- Surface Levels: 9 Random Control Points per Panel
- Width and Edge Alignment: Each Panel
- Joint Alignment: Each Panel
A7.3.8.6 Texture
The average depth of texture shall be between 3,0 and 4,5 mm as prescribed.

B7.3 REMOVAL AND REINSTATEMENT OF EXISTING CONCRETE LAYERS
CONTENTS
B7.3.1 SCOPE
B7.3.2 DEFINITIONS
B7.3.3 GENERAL
B7.3.5 MATERIALS
B7.3.8 WORKMANSHIP
B7.3.1 SCOPE
B7.3.2 DEFINITIONS
B7.3.3 GENERAL

B7.3.5 MATERIALS


B7.3.8 WORKMANSHIP

C7.3 REMOVAL AND REINSTATEMENT OF EXISTING CONCRETE LAYERS
(i) Preamble
Not applicable.
pay items.
km.
specifications.
items

C7.3.1 Removal of concrete in rehabilitation work
C7.3.1.1 Concrete without reinforcing cubic metre (m³)
C7.3.1.2 Reinforced concrete cubic metre (m³)
C7.3.1.3 Underlying layers cubic metre (m³)
The unit of measurement shall be a cubic metre of concrete or underlying pavement layers broken up and removed to an approved spoil site. The
quantity shall be determined in accordance with the authorized dimensions the particular pavement layer removed.
The tendered rate shall include full compensation for breaking up the concrete, loading, and transporting it to an approved spoil site and removing any
remaining debris ad cleaning the excavation as specified. No overhaul shall be applicable. The tendered rate shall also include full compensation for
the protection of adjacent concrete and its repair should it be damaged.
Dowels and tie bars in existing concrete and stays used to keep the bars in position will not be regarded as reinforcing.

C7.3.2 Full depth repairs using hand placed concrete with CEM I 52,5 cubic metre (m³)
The unit of measurement shall be the cubic metre of pavement placed by hand and finished in accordance with the specifications and Drawings,
and the quantity shall be the summation of the individual areas calculated by multiplying the length by the width at the top surface of the repaired
panel by the average depth of the repair. The tendered rate shall include full compensation for:
• Procuring, furnishing and storage of all materials
• Provision of all plant
• Saw cutting including both pilot and final cuts
• Epoxy filling of overcuts at corners
• Breaking out and removing concrete
• Cutting existing reinforcement as required
• Preparing subbase including cleaning out and priming
• Determination of mix proportions
• Mixing, transporting, placing and finishing of the concrete, including formwork where required
• Mesh reinforcement including cutting, waste and placing
• Mechanical texturing, curing and surface protection
• Disposal of surplus material and cleaning up
• Sampling and testing
In addition, the tendered rate shall also include full compensation for the preparation of joint faces in accordance with the specifications and
drawings and shall include following:
• Cleaning of joint faces
• Supply and application of bond-breaker
• Supply and application of wet to dry epoxy
• Installation of joint former where required
• Initial saw cutting for crack control where two panels are cast together
• Saw cutting for installation of silicone sealant
• Forming of central key at longitudinal construction joints
• Provision of all plant and materials
• Disposal of surplus materials and cleaning up
C7.3.3 Partial Depth Repairs using hand placed fine concrete cubic metre (m³)
The unit of measurement shall be the square metre of partial depth repair placed by hand and finished in accordance with the Contract
Documentation, and the quantity shall be the summation of the individual repair areas measured at the surface of the slab. The depth of the repair
shall be a minimum of 50 mm and a maximum of 75 mm.
The tendered rate shall include full compensation for:

• Sawcutting or routing
• Cleaning surfaces
• Supply and installation of polyethylene former to transverse and longitudinal weakened plane joints
• Supply and application of wet to dry epoxy
• Supply and application of bitumen bond-breaker as required
• Mixing, transporting, placing and finishing of the concrete including formwork where require
• Reforming longitudinal construction joints as required
• Sawcutting for the installation of silicone sealant
• Mechanical texturing, curing and surface protection
C7.3.4 Tie-bars and dowels for full depth repairs
C7.3.4.1 Tie bars (indicate diameter and length) number (No)
C7.3.4.2 Dowel bars (indicate diameter and length) number (No)
The unit of measurement shall be the number of tie-bars or dowels placed in accordance with the Drawings or as authorised by the Engineer.
The tendered rate shall include compensation for:

• Drilling and cleaning out of tie bar and dowel holes
• Supply and application of grout material
• Supply and application of bond breaker to dowels
• Supply, cutting and placing of tie-bars and dowels

C7.3.5 Partial Depth Repairs using hand placed acrylic resin grout square metre (m²)
The unit of measurement shall be the square metre of partial depth repair placed by hand and finished in accordance with the specifications and
drawings, and the quantity shall be the summation of the individual repair areas measured at the surface of the slab. The depth of the repair shall
be a minimum of 50 mm and a maximum of 75 mm.

• Sawcutting or routing
• Supply and installation of polyethylene former to transverse and longitudinal weakened-plane joints and application of any concrete
primer
• Mixing, transporting, placing and finishing of the acrylic epoxy grout including formwork where required
• Reforming joints as required
• Texturing, curing and surface protection
C7.3.6 Reinstating the subbase with lean mix concrete cubic metre (m³)
The unit of measurement shall be the cubic metre of lean mix concrete placed by hand and in accordance with the specifications and drawings.
The quantity shall be the summation of the individual areas calculated by multiplying the length by the width at the top surface of the repaired
subbase by the average depth of the repair.

• Preparing roadbed including cleaning out and priming
• Mixing, transporting, placing and finishing of the concrete, including formwork where required.
C7.3.7 Removal of exposed stitches in concrete pavement number (No)
The unit of measurement shall be number of exposed stitches removed from the concrete pavement as indicated by the Engineer. The tendered
rate shall include full compensation for widening the slot by means of saw cutting, removing the steel bar from the slot and cleaning the slot.
Damage to the concrete pavement shall be at the Contractor's expense.
Item Unit
C7.3.8 Sawing of concrete in rehabilitation works to different depths
C7.3.8.1 State depth in mm metre (m)
The unit of measurement shall be a square metre of saw-cut in the existing concrete as approved by the Engineer and sawn to the required depth,
measured once only irrespective of the number of times the sawing has to be repeated to obtain such depth. The quantity shall be the product of the
authorized length and depth of the saw-cut.
The tendered rate shall include full compensation for demarcating the saw line, providing and applying water and other material, and for sawing the
concrete to the satisfaction of the Engineer.
This item shall not apply to the sawing of joints.
C7.3.9 Removal of existing supporting layers in rehabilitation work
C7.3.9.1 Granular material cubic metre (m³)
C7.3.9.2 Cemented material cubic metre (m³)
C7.3.9.3 Asphalt material cubic metre (m³)
The unit of measurement shall be a cubic metre of concrete or underlying pavement layers broken up and removed to an approved spoil site. The
quantity shall be determined in accordance with the authorized dimensions the particular pavement layer removed.

The tendered rate shall include full compensation for breaking up the material, loading, and transporting it to an approved spoil site as well as removing
any remaining debris and cleaning the excavation as specified. No overhaul shall be applicable. The tendered rate shall also include full compensation
for the protection of adjacent concrete and its repair should it be damaged.
Dowels and tie bars in existing concrete and stays used to keep the bars in position will not be regarded as reinforcing.
C7.3.10 Preparing the underlying layers after the concrete has been removed
C7.3.10.1 Re-compaction of remaining underlying layers square metre (m²)
C7.3.10.2 Replacement of granular layers (material class and thickness indicated) square metre (m²)
C7.3.10.3 Replacement of stabilised layers (material class and thickness indicated) square metre (m²)
C7.3.10.4 Replacement of supporting layers with 10 MPa lean mix concrete (material class and square metre (m²)
thickness indicated)
C7.3.10.5 Replacement of subbase with hot mix asphalt (thickness indicated) ton (t)
C7.3.10.6 Levelling the surface with coarse slurry (micro surfacing) cubic metre (m³)
The unit of measurement shall be a square metre, cubic metre or ton, as relevant, of existing underlying layer prepared in accordance with the
requirements. The quantity shall be computed in accordance with the authorized dimensions of the prepared layer, or weigh bridge certificates as
relevant for asphalt.
The tendered rate shall include full compensation for preparing the layer in accordance with the specified requirements, testing for level, cleaning the
edge of the existing concrete and for removing any remaining loose material and waste.
C7.3.11 Reinstatement of concrete layers (Excluding texturing and curing)
C7.3.11.1 Replacement of concrete in JCP pavements (thickness indicated) square metre (m²)
C7.3.11.2 Replacement concrete in CRCP pavements (thickness indicated) square metre (m²)
C7.3.12 Pre-treating existing dowels
C7.3.12.1 Free ends in existing concrete number (No)
C7.3.12.2 Free ends in new concrete number (No)
The unit of measurement shall be the number of bars treated.
C7.3.13.1 Burlap-dragged and texture (indicate groove or broom finish) square metre (m²)
C7.3.13.2 Curing square metre (m²)
and curing compound as specified. The quantity shall be calculated from the specified horizontal dimensions of the completed concrete surface. The
tendered rate for texturing shall include full compensation for providing the plant and equipment required and for applying the specified surface texture.

The unit of measurement for steel bars shall be the ton of reinforcing steel in place in accordance with the drawings or as authorized.
authorized.
C7.3.16 Temporary Partial Depth Repairs using Asphalt Materials square metre (m²)
The unit of measurement shall be the square metre of repair at joint or surface spalling carried out in accordance with the specifications and
Drawing, and the quantity shall be the summation of the individual repair areas measured at the surface of the slab. The depth of the repair shall
be a minimum of 50 mm and a maximum of 75 mm.

• Provision of all plant and materials
• Supply and placing of hot or cold asphalt
The excavation and preparation of the repairs shall be paid for under C7.3.10.

D7.3 REMOVAL AND REINSTATEMENT OF EXISTING CONCRETE LAYERS
CONTENTS
D7.3.1 SCOPE
D7.3.2 GENERAL


7.4 REINSTATEMENT OF SLAB SUPPORT BY GROUT INJECTION
CONTENTS
A7.4.1 SCOPE
A7.4.2 DEFINITIONS
A7.4.3 GENERAL
A7.4.5 MATERIALS
A7.4.8 WORKMANSHIP

A7.4 REINSTATEMENT OF SLAB SUPPORT BY GROUT INJECTION

A7.4.1 SCOPE
This Section covers the work requirements for reinstatement of concrete pavement support by sub-sealing utilising grout injection. It also includes
for the jacking of concrete slabs to reinstate riding quality in areas of subgrade settlement and or faulting.
A7.4.2 DEFINITIONS
Sub-sealing - the filling of voids under the concrete pavement as a result of hydraulic erosion or other causes.
Slab jacking - the lifting of panels that have settled in order to reinstate ride quality.
A7.4.3 GENERAL
A7.4.3.1 Weather conditions
Sub sealing or slab jacking shall only be undertaken when the ambient temperature is 5°C and rising, and shall cease when the temperature exceed
30°C.

A7.4.4.1 Cement Grout Mixes
a) Grout Material
(i) Cementitious materials
Cementitious materials used for the grout shall comply with the following standards:
- Cement – SANS 50197-1. The cement type and class incorporated in the grout mix shall be appropriate to the setting times
required
- Ground Granulated Blast Furnace Slag - SANS 55167-1
- Fly ash - SANS 50450-1
- Silica fume - SANS 53263-1
(ii) Water
Water for use in the grout with SANS 51008. The requirements of Chapter 13 shall also apply.
The dry materials shall be accurately measured by weight or volume. If delivered in bulk they shall be packaged in bags of uniform
volume. The water shall be batched through an appropriate meter capable of measuring the day's consumption.

(iii) Grout
The grout material shall consist of the following:
• 1 part (by volume) CEM I cement
• 3 parts (by volume) Pozzolan or fly ash
• Sufficient water to achieve required fluidity
If ambient temperature is below 12°C an accelerator may be used subject to approval of the Engineer. Consideration of the time
required prior to opening the pavement to traffic shall be necessary.
b) Design process
The Contractor shall submit a design mix for materials and additives to be used as specified in this Clause. The mix design shall include physical
and chemical analysis for the pozzolans and tests of the grout slurry by an approved laboratory showing one day, three day, and seven day
strengths, flow cone times, shrinkage and expansion observed and time of initial test. The seven day compressive strength shall not be less than
4,0 MPa. The test specimens shall consist of the materials (including water and admixtures) which are to be used in the project.
c) Fluidity
Fluidity of the grout slurry shall be measured by the Corps of Engineers Flow Cone Method as per their specification CRD-C 611-80. Time of
efflux for pozzolanic grouts shall range from 16 to 26 seconds. A more fluid mix having a flow cone time of efflux of 9 to 15 seconds should be
used during the initial injection at each hole. These measurements shall be made not less than twice each day.
d) Grout for sealing of injection holes
Injection holes for sub-sealing and slab jacking shall be sealed with a cementitious grout as approved by the Engineer.
A7.4.4.2 Polyurethane foam

a) Grout Material
Polyurethane grout shall consist of two chemicals that combine to form a strong lightweight foam-like substance.
b) Design process
The Contractor shall submit a design for the foam indicating density of in excess of 64 kg/m3 and a strength in excess of 0,25 MPa.
c) Grout for sealing of injection holes
Injection holes for sub-sealing and slab jacking shall be sealed with a cementitious grout as approved by the Engineer.

The Contractor shall furnish all equipment necessary or incidental to the adequate performance and acceptable completion of the work as follows:
A7.4.5.1 Cement Grout

a) Grout plant
The grout plant shall consist of a positive displacement cement injection pump capable of applying 2 MPa pressure, a high-speed colloidal mixing
machine and a grout return system. The colloidal mixing machine shall operate at a minimum speed of 800 RPM, maximum speed to 2000 RPM,
creating a high-shearing action and subsequent pressure release to produce a homogeneous mixture.
b) Water tanker
If water tanker and pumps are not an integral part of the plant, water shall be supplied from a water truck with adequate capacity and pressure for
delivery to the grout plant.
c) Drilling equipment
An air compressor and rock drills or other device capable of drilling the grout injection holes 38 to 50 mm diameter through the concrete pavement
and stabilised subbase materials shall be required. The equipment shall be in good condition and operated in such manner that the holes are
vertical and not "cut-of-round". Down-feed pressure whether by hand or mechanical means shall not exceed 90 kg maximum downward pressure.
Holes shall be drilled in such a manner so as to prevent breakout at the bottom of the pavement.
In addition a coring machine shall be provided to take cores through the pavement and to drill pilot holes to prevent breakout on the concrete
pavement surface.
d) Transport
Transport required for the transportation of all materials, equipment and personnel required for the sub-sealing of the concrete pavement must
comply with all safety requirements and regulations applicable to vehicles operating on public roads.
e) Miscellaneous
All necessary hoses, valving and valve manifolds, positive cut-off and bypass provisions to control pressure and volume, pressure gauges and
gauge protectors, expanding packers and hoses to provide positive seal during grout injection, wood plugs, hole washing tools, steel drills and
bits shall be provided by the Contractor.

A7.4.5.2 Polyurethane Foam
a) Plant
When using polyurethane foam, all material is stored, proportioned, and blended within a self-contained pumping unit. All handling and usage of
these materials should be in accordance with the material manufacturer’s instructions and specifications.
b) Drilling equipment
For polyurethane slab stabilization, hand-held electric-pneumatic rock drills are typically used to drill the injection holes. For these procedures,
the maximum hole diameter should not exceed 15 mm.
In addition a coring machine shall be provided to take cores through the pavement and to drill pilot holes to prevent breakout on the concrete
pavement surface.
c) Transport
Transport required for the transportation of all materials, equipment and personnel required for the sub-sealing of the concrete pavement must
comply with all safety requirements and regulations applicable to vehicles operating on public roads.
d) Miscellaneous
All necessary hoses, valving and valve manifolds, positive cut-off and bypass provisions to control pressure and volume, pressure gauges and
gauge protectors, expanding packers and hoses to provide positive seal during grout injection, wood plugs, hole washing tools, steel drills and
bits shall be provided by the Contractor.

A7.4.6.1. Drilling holes
Holes for injection shall be drilled in a pattern determined by the Engineer in consultation with the Contractor. Holes shall be between 50 mm and
60 mm in diameter for cement grout and 15 mm diameter for polyurethane. They shall be drilled vertically and round and to a depth sufficient to
penetrate through the stabilised subbase but not more than 75 mm into the subgrade. Down-feed pressure, whether by hand or mechanical
means, shall be drilled in such a manner so as to prevent breakout at the bottom of the concrete pavement.
A7.4.6.2 Washing of holes

Holes shall be briefly washed to create a small cavity to allow for the initial spread of grout.
A7.4.6.3 Sub-sealing
The purpose of slab stabilization is to fill existing voids and not to raise the slab. Close inspection is required by the contractor and the inspector
during the stabilisation operation, as lifting of the slabs can create additional voids and may lead to slab cracking. The success of the slab
stabilisation operations is highly dependent upon the skill of the contractor.
The grout injection should start with a low pumping rate and pressure and should be pumped until one of the following conditions occurs:
• The maximum allowable pressure of 0,69 MPa at the grout plant is obtained. Note that a short surge up to 1,38 MPa can be allowed
when starting to pump in order for the grout to penetrate the void structure, if necessary.
• The slab lift exceeds 3,0 mm.
• Grout is observed flowing from adjacent holes, cracks, or joints.
• Grout is being pumped unnecessarily under the shoulder, as indicated by lifting.
• More than about 1 minute has elapsed (any longer than this indicates the grout is flowing into a cavity).
The uplift for any given slab corner should be monitored using a modified Benkelman Beam or other similar device that is capable of detecting
0,025 mm of uplift movement.
The effectiveness of slab stabilization can be determined only by monitoring the subsequent performance of the pavement. The best early
indication of effectiveness is obtained by measuring slab deflections before and after grouting to determine if the magnitude of the deflection has
been significantly reduced by the process. If the retesting still indicates a loss of support, the slabs should be regrouted using new drilled holes. If
voids are still present after three attempts to stabilize the slab, other methods of repair should be considered (e.g., full-depth repair).
A7.4.6.4 Slab-jacking
Procedures must be developed to monitor the raising of the slab and to ensure that the profile meets the desired grade. The taut stringline method
is an excellent way to not only control the pumping sequence, but also to achieve the proper grade.
In the stringline method, small wooden blocks, 19 mm (0,75 in) high, are set on the pavement surface along the outer and inner edges and a
stringline is secured at least 3,0 m (10 ft) from each end of the depression. As material pumping proceeds, the exact amount of rise at each point
within the sag can be observed, allowing the pumping at specific holes to be carefully controlled. This method can consistently achieve profiles
within tolerances of 6,0- to 9,0 mm (0,25- to 0,38 in).
• After all preliminary work has been completed (holes drilled, relief opening cut if needed), the pavement is ready to be raised. The slab
must be raised only a very small amount at each hole at a time. A good rule is not to raise a slab more than 6,0 mm (0,25 in) while
pumping in any one hole. No portion of the slab should be more than 6,0 mm (0,25 in) higher than any other part of the slab (or an
adjacent slab) at any time. The entire working slab and all those adjacent to it must be kept in the same plane, within 6,0 mm (0,25 in),
throughout the entire operation to avoid cracking.
• Pumping should be done over the entire section so that no great strain is developed at any one place. If, for example, pumping was
started at either end of a dip, the tension on the top surface will be increased, and the slab will undoubtedly crack. However, if pumping
is started at the middle where the tension is on the lower surface, lifting will tend to reduce it, and the slab can be raised an appreciable
amount without any damage. As the section is brought back to its original profile, the pumping is extended farther and farther in either
direction until the entire dip is at the desired elevation.

• Care must be taken not to flatten the middle out completely. This will cause a sharp bend and will cause cracking. The middle section
naturally must be raised faster than the ends of the dip, but lifting should be conducted in such a manner as to avoid sharp bends.
A7.4.6.5 Sealing of injection holes

In the case of cement grouting, After grouting has been completed at any one hole, the packer (expanding rubber used to seal the open space
between the grout injection pipe and the hole) shall be removed and the hole plugged immediately with a tapered wooden plug. These plugs are
only temporary and can be removed once the grout has set sufficiently to prevent back pressure from forcing the grout through the hole. Each
hole must be permanently sealed flush with the pavement surface with a cementitious grout or other material approved by the Engineer.
A7.4.6.6 Loss of grout

Excessive loss of grout/polyurethane during the sub-sealing and slab-jacking operations through other injection holes, joints and cracks or the
sides of the pavement shall not be paid for.
A7.4.6.7 Unanticipated conditions

In the event of the Engineer determines that continued injection at any specific location due to major voids is no longer economically feasible, he
should direct the Contractor to cease injection at the location. The Contractor will be paid at the unit price for the material used up to that point.
A7.4.6.8 Changed conditions

The Engineer, at his discretion, may delete any location or may add a new location to be sub-sealed or slab-jacked (raised). Variation in the plan
quantity at any specific location will not be considered cause for renegotiation of the unit prices.
A7.4.6.9 Finishing
All loose concrete, joint filler or grout/foam accidentally or otherwise spilled on the surface of the concrete pavement or on the adjoining gravel
shoulder/median and any other construction waste material shall be removed and the surrounding areas shall be left in a neat and orderly condition
by the Contractor prior to final acceptance of the work.
A7.4.7 WORKMANSHIP
A7.4.7.1 Level and Grade
The level tolerance on any portion of full depth fresh concrete cast between existing panels or portions thereof, shall be governed by the levels
on the adjacent edges of the existing concrete. Where the fresh concrete is a portion of an existing panel the level shall be checked by a 3,0 m
straight-edge placed across the existing concrete edges and the level of the fresh concrete shall not deviate by more than ± 3,0 mm from the line
of the straight-edge.
Where complete panels are replaced between existing joints, the longitudinal grade tolerance of each replaced panel shall be governed by the
longitudinal grade along the edge of adjacent concrete panels remaining in position. The concrete shall be finished flush with the adjacent panels
and the maximum deviation from the existing longitudinal grade shall not exceed ± 3,0 mm.
For thin bonded arris and surface repairs the fresh concrete shall be finished flush with the surrounding concrete to within a tolerance of ± 3,0
mm.
A7.4.7.2 Thickness
Where full depth panels or portions thereof, are replaced on top of the existing subbase layers, the nominal thickness of the concrete shall be
equal to the nominal thickness of the adjacent concrete pavement.
A7.4.7.3 Surface Regularity

Where single concrete panels or portions thereof are replaced between existing panels, no irregularity of more than 3,0 mm shall be measured
with a rolling straight-edge or a 3,0 mm long straight-edge laid along the centre line of the road.
A7.4.7.4 Testing frequency

For full-depth repairs the testing frequency for construction tolerances shall be as per the following:
- Surface Levels: 9 Random Control Points per Panel
- Width and Edge Alignment: Each Panel
- Joint Alignment: Each Panel

B7.4 REINSTATEMENT OF SLAB SUPPORT BY GROUT INJECTION
CONTENTS
B7.4.1 SCOPE
B7.4.2 DEFINITIONS
B7.4.3 GENERAL
B7.4.5 MATERIALS
B7.4.8 WORKMANSHIP
B7.4.1 SCOPE
B7.4.2 DEFINITIONS
B7.4.3 GENERAL

B7.4.5 MATERIALS


B7.4.8 WORKMANSHIP

C7.4 REINSTATEMENT OF SLAB SUPPORT BY GROUT INJECTION
(i) Preamble
None.
pay items.
km.
C7.4.1 Sub-sealing of the concrete pavement number of 50 kg

cement pockets
The unit of measurement shall be the number of 50 kg pockets of cement used to complete the sub-sealing operation. The tendered rate shall
include full compensation for supplying all the equipment and incidentals necessary to carry out the sub-sealing operation complete and shall
include for all pozzolans, fly ash, water and admixtures used in the grout mixture.
The tendered rate shall also include for the cleaning of the pavement surface of all debris and grout spillage, wooden plugs and the sealing of
joints and other openings where the grout may escape. The tendered rate shall also include full compensation for supplying all equipment,
materials and incidentals required to drill the holes, cleaning and monitoring the holes and to fill the holes with a suitable cement/fine aggregate
mix after the sub-sealing operation has been completed.

D7.4 REINSTATEMENT OF SLAB SUPPORT BY GROUT INJECTION
CONTENTS
D7.4.1 SCOPE
D7.4.2 GENERAL


7.5 REINSTATEMENT OF RIDING QUALITY
CONTENTS
A7.5.1 SCOPE
A7.5.2 DEFINITIONS
A7.5.3 GENERAL
A7.5.5 MATERIALS
A7.5.8 WORKMANSHIP

A7.5 REINSTATEMENT OF RIDING QUALITY

A7.5.1 SCOPE
This Section covers the work required to reinstate the smoothness/riding quality of concrete pavements.
A7.5.2 DEFINITIONS
Smoothness/riding quality – as measured by appropriate methods depending on the area/s being assessed, and may include:
- 3,0 m straight edge
- Rolling straight edge
- Direct Contact Roughness Measuring Devices
- High Speed Inertial Non-Contact Laser Profilometers
A7.5.3 GENERAL
In this Section, distinction is made as follows:
- Work required on newly placed concrete as a result of poor workmanship not meeting the required specifications
- Work required as a result of deficiencies in the existing concrete surface
In the case of poor workmanship, no payment for this work, including traffic accommodation and any additional riding quality measurements ordered
by the Engineer, shall be applicable.

Not applicable
A7.5.5 MATERIALS
Not applicable

Grinding shall be performed using diamond blades mounted on a self-propelled machine designed for grinding and texturing pavement. The
grinding equipment shall be at a minimum 35,000 pounds including the grinding head, and of a size that will grind a strip at least 3 feet wide. The

effective wheel base of the machine shall be no less than 12 feet. The effective wheel base is defined as the distance from the front wheel
assembly transverse pivot point to the transverse pivot point of the profile/depth control/ ground drive wheels.
The equipment shall have a positive means of vacuuming the grinding residue from the pavement surface, leaving the surface in a clean, near-
dry condition.
Grinding equipment that causes ravelling, aggregate fractures or disturbance to the joints shall not be permitted. The equipment shall be
maintained to ensure it is in proper working order.
The grinding process shall produce a pavement surface that is true in grade and uniform in appearance with longitudinal line-type texture. The
line-type texture shall contain corrugations parallel to the outside pavement edge and present a narrow ridge corduroy type appearance. The
peaks of the ridges shall be 3,0 mm +/- 1,5 mm higher than the bottom of the grooves with evenly spaced ridges.
Slurry shall be collected, processed and disposed of.

A7.5.7.1 Areas to be treated as a result of poor workmanship in new concrete
Where the smoothness of newly placed concrete does not meet the relevant specified requirements, the Contractor shall grind the surface utilising
appropriate equipment. If the grinding is carried out with 14 days of initial placing, new curing compound shall be applied as prescribed in Clause
A6.1.7.3 of Chapter 6.
The areas to be ground shall be identified by the Contractor and sufficiently improved so as to meet all the final smoothness requirements as specified.
No payment shall be applicable for these operations.
A7.5.7.2 Areas to be treated as a result of smoothness deficiencies in the existing concrete.

Where the smoothness of the existing surface is poor as a result of settlement, faulting or any other reason, the affected areas shall be ground to meet
the required tolerances as specified. The areas to be treated and level of smoothness required shall be as specified in the Contract Documentation
and as directed by the Engineer.
Payment for grinding shall be in accordance with Part C: Measurement and Payment.
The areas to be treated shall be as indicated in the Contract Documentation and as directed by the Engineer. Depending on the depth of grinding
required, and the equipment being utilised, it may be necessary to apply more than one pass of the grinding machine to achieve the specified
requirements.
A7.5.8 WORKMANSHIP
After completion of the grinding, the finished surface shall comply with all the smoothness requirements as specified in Clause A6.1.8 of Chapter 6 as
relevant, or any other requirement as may be specified in the Contract Documentation.

B7.5 REINSTATEMENT OF RIDING QUALITY
CONTENTS
B7.5.1 SCOPE
B7.5.2 DEFINITIONS
B7.5.3 GENERAL
B7.5.5 MATERIALS
B7.5.8 WORKMANSHIP
B7.5.1 SCOPE
B7.5.2 DEFINITIONS
B7.5.3 GENERAL

B7.5.5 MATERIALS


B7.5.8 WORKMANSHIP

C7.5 REINSTATEMENT OF RIDING QUALITY
(i) Preamble
None.
pay items.
km.
C7.5.1 Grinding of existing concrete pavement surfaces square metre (m²)
The unit of measurement shall be the square metre of surface treated. The tendered rate shall include full compensation for establishing the
appropriate equipment on site, grinding as required and disposing all removed material and or debris from the site to an approved spoil site.

D7.5 REINSTATEMENT OF RIDING QUALITY
CONTENTS
D7.5.1 SCOPE
D7.5.2 GENERAL


7.6 REINSTATEMENT OF SURFACE TEXTURE
CONTENTS
A7.6.1 SCOPE
A7.6.2 DEFINITIONS
A7.6.3 GENERAL
A7.6.5 MATERIALS
A7.6.8 WORKMANSHIP

A7.6 REINSTATEMENT OF SURFACE TEXTURE

A7.6.1 SCOPE
This Section covers all work in connection with the retexturing of a concrete pavement surface by means of grooving the concrete surface in the
transverse direction perpendicular to the centre line of the road.
A7.6.2 DEFINITIONS
Texture/mean profile depth – consisting of randomly spaced grooves formed in fresh concrete or sawn into hardened concrete normally 3,0 to 5,0
mm in depth.
A7.6.3 GENERAL
In this Section, distinction is made as follows:
- Work required on newly placed concrete as a result of poor workmanship not meeting the required specifications
- Work required as a result of deficiencies in the existing concrete surface
In the case of poor workmanship, no payment for this work, including traffic accommodation and any additional texture depth measurements required,
shall be applicable.

Not applicable
A7.6.5 MATERIALS
Not applicable

Self-propelled machines with multi-blade arbors utilising diamond blades built for grinding and/or retexturing purposes. Each machine is to be
equipped with a depth control device to ensure that the grooving depth is maintained, as well as a device to control the alignment. Governing
machine speed is required to maintain an even depth.
The sawing equipment shall be appropriate for the depth of texturing required and surface area to be treated. The blades utilised shall be 3,0 mm
in thickness and so configured so as to provide grooves at random spacing 12 to 25 mm apart.

A7.6.7 EXCECUTION OF THE WORKS
A7.6.7.1 Areas to be treated as a result of poor workmanship in new concrete
Where the texture depth of newly placed concrete is too shallow or irregular, and does not meet the relevant specified requirements, the Contractor
shall saw grooves into the pavement surface utilising appropriate equipment. The surface texture shall then be reinstated to the specified depth of 3,0
to 5,0 mm. If the texture sawing is carried out on the surface within 14 days of initial placing, new curing compound shall be applied as prescribed in
Clause A6.1.7.3 of Chapter 6. The areas to be retextured, as identified by the Engineer, shall be treated by the Contractor so as to meet all the final
texture requirements as specified.
No payment shall be applicable for these operations.
A7.6.7.2 Areas to be treated as a result of texture deficiencies in the existing concrete.

Where the texture of the existing surface is inadequate as a result of abrasion, or any other reason, the identified areas shall be retextured to meet
the required tolerances as specified. The areas to be treated and texture depth required shall be as specified in the Contract Documentation and as
Payment for retexturing shall be in accordance with Part C: Measurement and Payment.
A7.6.7.3 General requirements

All residue or slurry resulting from the texturing operation be removed continuously. The pavement shall be left in a clean washed condition
immediately after the operation and no slurry shall be allowed to flow over lanes open to traffic, or into the drainage system
In order to improve the surface drainage texturing shall be done up to the edge of the pavement to enable surface water to run off the pavement
completely.
A guide line shall be required to be set at the start of each section to ensure that grooves are perpendicular to the centre line of the road. Where
horizontal curves are encountered it is necessary to set out guide wires at 2,0 m intervals.
A7.6.8 WORKMANSHIP
The average depth of the grooves, as measured with a tyre tread depth gauge, shall be 4,0 mm and within the range of 3,0 to 5,0 mm and at a random
spacing between 12 and 25 mm.
Groove depth is the most important component that needs to be evaluated constantly, of importance in this respect is machine speed. At high
speeds blades tend to lift out of the concrete and shallow groove depths are obtained.
A minimum of 3 measurements per lane at random positions will be taken with a digital calliper at hourly intervals. The average depth, standard
deviation and coefficient of variation for every sample will be taken.
Allowable tolerances shall be as follows:
Groove width: 3,5 mm +-0,5 mm
Groove depth: 4,5 mm +-1,5 mm

B7.6 REINSTATEMENT OF SURFACE TEXTURE
CONTENTS
B7.6.1 SCOPE
B7.6.2 DEFINITIONS
B7.6.3 GENERAL
B7.6.5 MATERIALS
B7.6.8 WORKMANSHIP
B7.6.1 SCOPE
B7.6.2 DEFINITIONS
B7.6.3 GENERAL

B7.6.5 MATERIALS


B7.6.8 WORKMANSHIP

C7.6 REINSTATEMENT OF SURFACE TEXTURE
(i) Preamble
None.
pay items.
km.
C7.6.1 Retexturing of concrete surfaces (transverse or longitudinal) square metre (m²)
The unit of measurement shall be a square metre of saw-cut texturing in the existing concrete surface according to the groove specifications, measured
once only irrespective of the number of times the sawing has to be repeated to obtain such depth.
The tendered rate shall include full compensation for demarcating the saw line, providing equipment and applying water or any other material. The
rate shall also include for the protection of the adjacent road verge and subsequent disposal of the paste at an approved spoil site.

D7.6 REINSTATEMENT OF SURFACE TEXTURE
CONTENTS
D7.6.1 SCOPE
D7.6.2 GENERAL


South Africa
COTO
Officials

Draft Standard (DS)

CHAPTER 8: PRETREATMENT
AND REPAIR OF EXISTING
LAYERS
October 2020

FOREWORD

Published by:
The document with its Chapters is provided as a Draft Standard (DS) without any warranty of any kind, expressed or implied. No
warranty or representation is made, either expressed or implied, with respect to fitness of use and no responsibility will be

industry.
Document versions:
Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 8: PRETREATMENT AND REPAIR OF EXISTING LAYERS .................................................................. 8-1
8.1 PRIME COAT ......................................................................................................................................................... 8-1
PART A: SPECIFICATIONS .................................................................................................................................................................................. 8-1
PART B: LABOUR ENHANCEMENT ..................................................................................................................................................................... 8-4
PART C: MEASUREMENT AND PAYMENT ......................................................................................................................................................... 8-5
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES ............................................................................................................................ 8-7
8.2 COVER SPRAYS, FOG SPRAYS AND REJUVENATION SPRAYS ................................................................... 8-8
PART A: SPECIFICATIONS .................................................................................................................................................................................. 8-8
PART B: LABOUR ENHANCEMENT ................................................................................................................................................................... 8-10
PART C: MEASUREMENT AND PAYMENT ....................................................................................................................................................... 8-11
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES .......................................................................................................................... 8-13
8.3 TEXTURE TREATMENT ...................................................................................................................................... 8-14
PART A: SPECIFICATIONS ................................................................................................................................................................................ 8-14
8.4 RUT AND/OR DEPRESSION CORRECTION ..................................................................................................... 8-19
8.5 STANDARD CRACK SEALING........................................................................................................................... 8-25
8.6 GEOSYNTHETIC CRACK SEALING .................................................................................................................. 8-31
8.7 PLANING .............................................................................................................................................................. 8-36
8.8 PATCHING AND EDGE BREAK REPAIR .......................................................................................................... 8-42
8.9 REPAIR OF SURFACE DEFECTS ...................................................................................................................... 8-50
CHAPTER 8: PRETREATMENT AND REPAIR OF EXISTING LAYERS
8.1 PRIME COAT
CONTENTS
A8.1.1 SCOPE
A8.1.2 DEFINITIONS
A8.1.3 GENERAL
A8.1.5 MATERIALS
A8.1.8 WORKMANSHIP

A8.1 PRIME COAT

A8.1.1 SCOPE
This Section covers the work in connection with the application of a prime coat.
A8.1.2 DEFINITIONS
Prime coat - consists of a low viscosity bituminous binder, applied in a single application on a granular, cemented or treated base or subbase to
facilitate a good bond between the base and the bituminous surfacing or subbase and bitumen treated base.
A8.1.3 GENERAL
No prime shall be applied under the following adverse conditions:
• During foggy or wet conditions;
• When rain is imminent;
• When wind is blowing sufficiently hard to cause uneven spraying;
• When the surface of the layer is visibly wet, i.e. more than damp;
• When the temperature of the surface immediately prior to commencing with the application of the prime is below, or in the opinion of the
Engineer, likely to fall below 10°C;
• After sunset;
• When at any position within the layer the moisture content of a granular base layer is more than 50 % of the optimum moisture content
determined according to SANS 3001 No GR30. In the event of rain after priming, the base shall be allowed to dry out to meet the above
moisture content requirements prior to surfacing. Limiting moisture contents for treated layers before priming shall be specified in the
A8.1.3.2 Nominal rate of prime coat application

The nominal rate of application, for tender purposes, shall be 0,8 l/m2.

All specifications for prime coats addressed in this Section shall apply.
The selection of the appropriate prime coat type shall be based on good practice guidelines regarding the early performance of different products
applied, as described in Clause A8.1.5.1.
A8.1.5 MATERIALS
A8.1.5.1 Bituminous material
The priming material shall be one of the following as specified in Part C: Measurement and Payment:
Table A8.1.5-1: Bituminous binder for priming the excavated area
Bituminous binder for priming the excavated area Specification
MC-10 cut-back bitumen SANS 4001 – BT2
MC-30 cut-back bitumen SANS 4001 – BT2
Inverted bitumen emulsion SANS 4001 – BT5
Certified by independent
Other appropriate product containing solvents
certification agency
Certified by independent
Other appropriate product containing no solvents
certification agency
The type of prime and application rate best suited for the base shall be determined after construction of the base. The Contractor shall provide
about 20 ℓ of at least three prime products and apply it at different application rates with a brush on the base. The Engineer shall evaluate the
performance of the prime in accordance with the latest version of TRH1/SABITA Manual 26 and then instruct the type of prime and application
rate to be applied. No payment shall be made for tests to determine the appropriate priming product.
A8.1.5.2 Aggregate for blinding primed layers

Where so instructed, blinding material shall consist of crusher sand or natural sand, with 100 % passing the 7,1 mm sieve and not more than 10 %
passing the 2,0 mm sieve. The aggregate shall be clean, hard and free from excessive dust and shall contain no clay, loam or other deleterious
matter.
Blinding of the primed surface with such aggregate at a nominal rate of 285 m²/m³ shall only be permitted to facilitate traffic accommodation or
access arrangements.

The equipment specifications as prescribed in Clause A10.1.6.1 of Chapter 10, are applicable.

A8.1.7.1 Preparation of the layer to be primed
Not longer than 24 hours before spraying, the layer to be primed shall be broomed and cleaned of all loose or deleterious material by means of a
controlled rotary broom and/or hand brooms. Sweeping shall be done carefully so as not to cause any damage to the layer. A light spray of water,
sufficient to dampen the surface, shall be uniformly applied to the layer immediately before the application of the prime. If the water is over
applied, resulting in standing water, the layer shall be allowed to dry until a uniform damp surface is obtained.
Before any priming material is sprayed, the layer to be primed shall be checked for conformance with the surface and other requirements
specified.
A8.1.7.2 Storage and application of the prime coat

The temperatures for storage and spraying shall be in accordance with the relevant SANS 4001 specifications or be in accordance with the
manufacturer's specifications or as required by a product's certification documentation.
All prime materials stored in a heated condition shall be stored in a tank with a properly functioning circulation system and having a securely fitting
lid.
All layers where the application of a prime is specified or ordered shall be primed using a mechanical distributor complying with Clause A10.1.6.1
of Chapter 10. The edges of the previously constructed or existing surfacing shall be adequately protected by approved means to ensure that an
overlap of prime not exceeding 50 mm is achieved.
A mat of reinforced paper or other suitable approved material shall be used at all joints at the beginning and end of all sprays to obtain a neat start
and cut-off.
If the prime is applied in more than one strip, allowance shall be made for overlapping of strips by 200 mm, in accordance with the triple spray flair
configuration, to ensure a full application of the prime over the joint.
Unless directed otherwise by the Engineer or indicated on the drawings, the edges of the primed surface shall be 200 mm wider than the edges of
the surfacing. The edges of the primed surface shall be true to line with a maximum deviation of 25 mm from the specified edge line.

Wherever feasible, the prime shall be applied in one or more lanes evenly over the full width of the road and allowed to penetrate and cure until
traffic can pass over the surface without any pickup. All traffic shall be kept off the surface until this condition is obtained.
Where it is not feasible for traffic to use diversions, the prime shall be applied and allowed to penetrate for as long as is practicable before a blinding
layer of aggregate is applied at a nominal rate of 285 m²/m³. Care shall be exercised in this operation to avoid the aggregate being applied too
soon after spraying the prime. Any “caking” of aggregate which may take place and cause problems during the surfacing process and all loose
aggregate shall be removed before the final surfacing is applied.
Where it is not possible to construct such ancillary works after priming, care shall be taken to protect all kerbing, channeling and guard rails from
the prime by covering them with suitable protective material when spraying. The Contractor shall, at his own cost, replace all soiled items. Painting
of the soiled surfaces shall not be accepted as a suitable remedial measure.
A8.1.7.3 Areas inaccessible to mechanical equipment

The provisions of Clause A10.1.3.3 of Chapter 10 shall apply to the application of the prime in areas inaccessible to mechanical equipment. The
prime shall be applied by means of a portable binder distributor that complies with the requirements of Clause A10.1.6.1 of Chapter 10. The
quantity of prime applied shall be controlled so that the specified rate of application is achieved. Surplus prime shall be removed as specified in
Clause A8.1.7.4.
A8.1.7.4 Removal of surplus prime

After the prime has penetrated sufficiently, surplus prime shall be covered with damp crusher sand, which shall be worked into it by means of
hand brooms to absorb the surplus prime. As soon as it is saturated with prime, the crusher sand shall be swept off the primed surface and the
area allowed to dry before surfacing. The process shall be repeated until no surplus prime or wet prime remains on the surface.
A8.1.7.5 Opening to traffic

Where a blinding layer is specified in the drawings or directed by the Engineer, and applied to the primed surface, the Contractor shall maintain the
blinding layer and the primed surface during the period when the surface is opened to traffic and shall repair all damage caused to the surface by
such traffic, as directed by the Engineer, at no additional payment.
Traffic accommodation shall comply with the specifications in Section A1.5 of Chapter 1.
A8.1.8 WORKMANSHIP
A8.1.8.1 Tolerances
The actual spray rates measured at spraying temperature shall not deviate by more than 8,0 % from that ordered by the Engineer. The Engineer
may conditionally accept application rates falling outside this tolerance at reduced payment in accordance with Table A8.1.8-1. Conditional
acceptance shall not relieve the Contractor of his contractual obligations.
A8.1.8.2 Testing
The Contractor shall give the Engineer at least 24 hours’ notice of his intention to spray prime material so that the actual spray rates can be
verified and approved by the Engineer. Unless otherwise agreed in advance, the Contractor shall only spray when the Engineer’s representative is
present.
The Contractor shall provide, at his cost, representative samples of every batch of prime delivered onto site.
Table A8.1.8-1: Payment reduction factors for conditionally accepted prime coat
Deviation specified spray rate at spraying Payment reduction factor of
temperature (%) tendered rate
±8,0 1.00
±9,0 0.97
±10,0 0.95
±11,0 0.90
±12,0 0.85
±13,0 0.80
Any deviation outside these limits shall not be paid for however, the Engineer shall have the right to instruct the Contractor to make up any
deficiency, or blind excessive prime without additional payment. If under-spraying occurs, and it is accepted by the Engineer, only the actual
quantities applied shall be paid for.

B8.1 PRIME COAT
CONTENTS
B8.1.1 SCOPE
B8.1.2 DEFINITIONS
B8.1.3 GENERAL
B8.1.5 MATERIALS
B8.1.8 WORKMANSHIP
B8.1.1 SCOPE
A large proportion of activities as defined in Part A under the various sections are considered labour intensive. Therefore, Part B only provides
additional specifications, not contained in Part A.
B8.1.2 DEFINITIONS
B8.1.3 GENERAL

B8.1.5 MATERIALS

For application of prime coats, a hand operated spray cart with a 210 ℓ drum holder or similar, the use of spray tanker towed with a tractor or bakkie
with the necessary pumping equipment may be used in labour enhanced alternatives.

For prime coats, all preparation activities (sweeping, watering and protection of kerbs and roadside furniture are suitable components for labour
enhancement.
B8.1.8 WORKMANSHIP
Unless revised tolerances are specified in the Contract Documentation, the provisions of Part A shall apply.

C8.1 PRIME COAT
(i) Preamble
3. No additional payment shall be made, nor shall any claim for additional payment be considered, for any specified work in confined or
restricted areas. Any additional costs associated with working in confined or restricted areas shall be deemed to be included in the standard
applicable pay items.
km.
9. Removal of surplus prime.
C8.1.1 Prime coat:
C8.1.1.1 MC -10 cut-back bitumen litre (ℓ)
C8.1.1.2 MC -30 cut-back bitumen litre (ℓ)
C8.1.1.3 Inverted bitumen emulsion litre (ℓ)
C8.1.1.4 Certified product containing solvents (State name) litre (ℓ)
C8.1.1.5 Certified product containing no solvents (State name) litre (ℓ)
The unit of measurement shall be the litre of priming material measured at spraying temperature and sprayed as required.
The tendered rates shall include full compensation for supplying the priming material, cleaning and watering the layer to be primed, applying the
priming material and maintaining the primed surface as specified.
C8.1.2 Aggregate for blinding:
C8.1.2.1 Natural sand cubic metre (m3)
C8.1.2.2 Crusher sand cubic metre (m3)
The unit of measurement shall be the cubic metre of aggregate used for blinding on the instructions of the Engineer.
The tendered rate shall include full compensation for procuring, furnishing and applying the aggregate for blinding where directed by the Engineer

and for maintenance of the blinding layer, as specified.
C8.1.3 Extra over item C8.1.1 for applying the prime coat accessible only to hand-held or litre (ℓ)
light equipment
The unit of measurement shall be the litre of priming material measured at spraying temperature and sprayed in accordance with the requirements
for areas accessible only to hand-held or light equipment and shall include for all additional costs.

D8.1 PRIME COAT
CONTENTS
D8.1.1 SCOPE
D8.1.2 GENERAL
D8.1.10 REMEDIAL WORK
D8.1.1 SCOPE
Pretreatment and repair of existing layers form an integral part of the final surfacing. Therefore, the relevant requirements of Part D in Chapter 9
and Chapter 10 shall apply.
D8.1.2 GENERAL
Not applicable to pretreatment works.









8.2 COVER SPRAYS, FOG SPRAYS AND REJUVENATION SPRAYS
CONTENTS
A8.2.1 SCOPE
A8.2.2 DEFINITIONS
A8.2.3 GENERAL
A8.2.5 MATERIALS
A8.2.8 WORKMANSHIP

A8.2 COVER SPRAYS, FOG SPRAYS AND REJUVENATION SPRAYS

A8.2.1 SCOPE
This Section covers the work in connection with the application of cover sprays, fog sprays and rejuvenation sprays.
A8.2.2 DEFINITIONS
Cover spray - refers to the application of a diluted emulsion as a final binder application on single or double seals or before application of the
slurry, in case of Cape seals.
Fog spray or rejuvenation spray - is used for the application of diluted anionic emulsion or rejuvenator for purposes of adding additional binder to
the seal or rejuvenating the seal at a later stage of the seal life.
The convention for describing diluted emulsion in this document is to state the type of emulsion with the proportion of emulsion and water in
brackets e.g. 65 % cationic emulsion (60/40), which defines the mix as 60 % of the cationic emulsion and 40 % water.
A8.2.3 GENERAL
Fog sprays in the form of diluted anionic emulsion or inverted bitumen emulsion are applied during the service life of an existing bituminous
surfacing to add additional binder or to rejuvenate the existing binder. Fog sprays using stable grade diluted anionic emulsions are applied as a
pretreatment prior the application of a surfacing seal, if specified.
Diluted cationic spray grade emulsions are used as cover sprays during seal construction or shortly thereafter where the seal is sensitive to
aggregate loss.

Weather limitations as specified in Clause A10.1.3.2 of Chapter 10 shall apply.
A8.2.3.2 Nominal rate of application for cover sprays, fog sprays and rejuvenation sprays
The nominal rate of application for tender purposes shall be:
a) Diluted cationic emulsion cover spray at 1,0 l/m2
b) Diluted anionic or cationic emulsion cover spray, in the case of Cape seals, at 0,8 l/m2
c) Diluted anionic emulsion fog spray as enrichment treatment at 0,8 l/m2
d) Rejuvenation spray with cut-back inverted emulsion or other Agrément certified products at 0,5 l/m2

All specifications for cover sprays, fog sprays and rejuvenation sprays relevant to this Section shall apply.
The selection of the appropriate product and application rates are only applicable to alternatives offered by the contractor or if design by the
Contractor is a specific requirement in the Contract Documentation. The proposed product and application rate shall be submitted to the
Engineer, for approval based good practice guidelines.
A8.2.5 MATERIALS
A8.2.5.1 Bitumen
a) Cover spray
Diluted 65 % cationic spray grade emulsion, or 60 % anionic stable grade emulsion, with the dilutions as specified in Part C: Measurement and
Payment.
b) Fog spray as enrichment treatment
A diluted 60 % anionic stable-grade emulsion (50/50) shall be used.
c) Rejuvenation spray
Agrément SA certified products or inverted bitumen emulsion complying with SANS 4001 – BT5, with the exception that the Viscosity at 60 °C on
residue from distillation shall be between 10 and 20 Pas.

Plant and equipment as specified in Clause A10.1.6.1 of Chapter 10 shall apply.

A8.2.7.1 Preparation and execution
The areas to be treated shall be cleaned of all dust, dirt, dung, oil or any other foreign matter.
The treatment shall consist of the application of a cover spray, fog spray or rejuvenation spray of the specified grade and dilution of bituminous
emulsion to the existing surface, by means of a pressure distributor, at the rates of application as specified in the Contract Documentation or as
directed by the Engineer, in widths that may vary from 0,5 m to 4,0 m.
A water tanker with a pressure distributor shall be available on standby for pre-wetting or post-wetting the areas scheduled for fog spray.

Treated sections shall only be opened to traffic when the emulsion has properly cured and tackiness has reduced to the extent that no pickup
occurs. Should pick-up occur after opening, immediate action is required by the Contractor to stabilise the situation through closure, water
spraying or blinding with approved coarse sand.
Traffic accommodation shall comply with the specifications in Clause A1.5 of Chapter 1.
A8.2.8 WORKMANSHIP
The requirements of Clauses A10.1.3.9 and A10.1.3.4 of Chapter 10 regarding joints between sprayed strips and the protection of kerbs,
channels, barriers, any structures, etc, shall apply.

B8.2 COVER SPRAYS, FOG SPRAYS AND REJUVENATION SPRAYS
CONTENTS
B8.2.1 SCOPE
B8.2.2 DEFINITIONS
B8.2.3 GENERAL
B8.2.5 MATERIALS
B8.2.8 WORKMANSHIP
B8.2.1 SCOPE
B8.2.2 DEFINITIONS
B8.2.3 GENERAL

B8.2.5 MATERIALS

Where reference is made in Part A to appropriate equipment in restricted areas, the use of light equipment shall be evaluated during trial sections.
For application of cover sprays, fog sprays and rejuvenation sprays, a hand operated spray cart with a 210 ℓ drum holder or similar, or a spray
tanker towed with a tractor or bakkie with the necessary pumping equipment, may be used in labour enhanced alternatives.

For cover sprays, fog sprays and rejuvenation sprays, all preparatory activities (sweeping, watering and protection of kerbs and roadside furniture
are suitable components for labour enhancement.
Given the light applications, hand spraying is not considered to be suitable for hand work except in restricted areas.
B8.2.8 WORKMANSHIP

C8.2 COVER SPRAYS, FOG SPRAYS AND REJUVENATION SPRAYS
(i) Preamble
km.
C8.2.1 Cover sprays, fog sprays and rejuvenation sprays
C8.2.1.1 65 % Cationic spray grade emulsion
(a) Indicate dilution (Diluted ..% Emulsion/…% Water) litre (ℓ)
C8.2.1.2 60 % Anionic stable grade emulsion
C8.2.1.3 Cutback Inverted bitumen emulsion litre (ℓ)

C8.2.1.4 Certified rejuvenator (State type and certification) litre (ℓ)
The unit of measurement shall be the litre of binder measured at spraying temperature and sprayed in accordance with the requirements.
The tendered rates shall include full compensation for cleaning and preparing the existing surface, for furnishing the material and applying the
binder and for all other incidentals necessary for completing the work as specified.
C8.2.2 Extra over item C8.2.1 for labour enhanced application
C8.2.2.1 65 % Cationic spray grade emulsion
C8.2.2.2 60 % Anionic stable grade emulsion

C8.2.2.3 Cutback inverted bitumen emulsion litre (ℓ)
C8.2.2.4 Certified rejuvenator (State type and certification) litre (ℓ)

D8.2 COVER SPRAYS, FOG SPRAYS AND REJUVENATION SPRAYS
CONTENTS
D8.2.1 SCOPE
D8.2.2 GENERAL
D8.2.1 SCOPE
Pretreatment and repair of existing layers form an integral part of the final surfacing. Therefore, the relevant requirements of Part D in Chapters 9
D8.2.2 GENERAL









8.3 TEXTURE TREATMENT
CONTENTS
A8.3.1 SCOPE
A8.3.2 DEFINITIONS
A8.3.3 GENERAL
A8.3.5 MATERIALS
A8.3.8 WORKMANSHIP

A8.3 TEXTURE TREATMENT

A8.3.1 SCOPE
This Section covers the work in connection with the application of texture treatments.
A8.3.2 DEFINITIONS
Texture treatment - refers to the application of a thin layer of slurry or microsurfacing to obtain a uniform fine texture prior to surfacing or
resurfacing.
A8.3.3 GENERAL
This treatment shall be used where the existing surface macro texture is coarse or varying to such an extent that one single and uniform binder
application rate for the seal to follow could result in the poor performance of the seal.

Weather limitations applicable to slurry seals, as specified in Clause A8.1.3.1, shall apply.
A8.3.3.2 Nominal rate of application for texture treatments

Nominal rates for tender purposes shall be in accordance with Table A8.3.3-1.
Table A8.3.3-1: Nominal rates for application of texture treatments
Component Nominal rate
Texture slurry application on existing macro texture of 1,0 mm to 2,0 mm 0,003 m³/m²
Texture slurry application on existing macro texture of 2,0 mm to 4,0 mm 0,0045 m³/m²
Microsurfacing application on existing macro texture up to 6,0 mm 0,007 m³/m²
Emulsion content for the texture slurry 200 l/m3
Emulsion content for the microsurfacing 180 l/m3
Active filler content of the texture slurry 16.5 kg/m3

All specifications for texture treatments relevant in this Section shall apply. The Contractor shall submit the proposed mix design for approval.
A8.3.5 MATERIALS
A8.3.5.1 Bitumen
a) The bituminous binder for conventional slurry shall be a 60 % stable-grade anionic bitumen emulsion complying with SANS 4001 – BT3.
b) The bituminous binder for microsurfacing shall comply to the specifications of Clause A10.1.5.5 of Chapter 10.
A8.3.5.2 Aggregate
a) Aggregate for texture slurry shall comply with the specifications of Clause A10.15.17a) of Chapter 10 for fine slurry, fine grade or medium
grade.
b) Aggregate for texture treatment with microsurfacing shall comply with the specifications of Clause A10.15.18 of Chapter 10 for Type II
grading.
A8.3.5.3 Active filler for slurry

The active filler shall comply with the specifications of Clause A10.1.5.17b) of Chapter 10.

Plant and equipment shall comply with the specifications of Clause A10.1.6.8 of Chapter 10.

The bituminous slurry shall be prepared, mixed and applied as specified in Clauses A10.1.6.8, A10.1.6.11 and A10.1.6.12 of Chapter 10.
The slurry shall be applied by hand and worked into cracks or other open patches with brooms or squeegees until the surface is smooth and even.

The road shall be exposed to traffic before further surface treatment work is carried out for such period as defined in Clause A10.1.3.11 of Chapter
10, or until such time that the representative ball penetration value (SANS 3001-BT10) at expected operating temperature (refer SABITA Manual
40) road surface temperature, reduces to less than 2,0 mm.
A8.3.8 WORKMANSHIP
The requirements of Clause A10.1.8 of Chapter 10 shall apply.

B8.3 TEXTURE TREATMENT
CONTENTS
B8.3.1 SCOPE
B8.3.2 DEFINITIONS
B8.3.3 GENERAL
B8.3.5 MATERIALS
B8.3.8 WORKMANSHIP
B8.3.1 SCOPE
B8.3.2 DEFINITIONS
B8.3.3 GENERAL

B8.3.5 MATERIALS
The provision of Part A shall apply.

Plant and equipment shall comply with the specifications of Clause B10.1.6.3 of Chapter 10. Where reference is made to appropriate or approved
equipment, the use of light equipment shall be evaluated during trial sections.

The provision of Part A shall apply.
B8.3.8 WORKMANSHIP

C8.3 TEXTURE TREATMENT
(i) Preamble
km.
9. Rolling of the microsurfacing.
C8.3.1 Texture treatment

C8.3.1.1 Application of slurry for texture improvement, applied by hand (Indicate aggregate grade, cubic metre (m³)
type of emulsion, filler type)
C8.3.1.2 Application of slurry for texture improvement, applied by spreader box (Indicate aggregate cubic metre (m³)
grade, type of emulsion, filler type)
C8.3.1.3 Application of microsurfacing for texture improvement, applied by spreader box (Indicate cubic metre (m³)
aggregate grade, type of emulsion, filler type)
The measurement for slurry shall be the cubic metre of saturated fine aggregate used, measured as described in item C10.1.20 of Chapter 10.
The tendered rates shall include full compensation for procuring and furnishing all the materials, for mixing and applying the slurry, demarcating all
areas to be treated and for all plant, labour and incidentals necessary to complete the work as specified.

D8.3 TEXTURE TREATMENT
CONTENTS
D8.3.1 SCOPE
D8.3.2 GENERAL
D8.3.1 SCOPE
D8.3.2 GENERAL









8.4 RUT AND/OR DEPRESSION CORRECTION
CONTENTS
A8.4.1 SCOPE
A8.4.2 DEFINITIONS
A8.4.3 GENERAL
A8.4.5 MATERIALS
A8.4.8 WORKMANSHIP

A8.4 RUT AND/OR DEPRESSION CORRECTION

A8.4.1 SCOPE
This Section covers the work in connection with rut and/or depression correction before resurfacing.
A8.4.2 DEFINITIONS
Rut correction - refers to filling of ruts in the wheel tracks
Screeding - refers to level correction using coarse slurry, microsurfacing or asphalt where the road surface is uneven and where depressions,
humps or small grooves occur as a result of deformation of the pavement layers not due to structural failure of the pavement.
A8.4.3 GENERAL
Where both planing and screeding are specified, the screed shall only be placed after the planing has been completed.
When asphalt is specified for rut filling or screeding, longitudinal keys shall be cut in accordance with the Contract Documentation.
The existing surface shall be swept clean or cleaned by other approved methods to be free from dust, soil, gravel, loose stones or any other
undesirable materials. If required, due to brittleness and permeability of the existing surface, a fog spray in accordance with Section A8.2 shall be
applied as pre-treatment.
The bituminous material used for the screed shall be asphalt, coarse slurry or microsurfacing as specified in the Contract Documentation.
The design of asphalt shall be in accordance with TRH8, and the coarse slurry and microsurfacings in accordance with SABITA Manual 28 and
shall be submitted to the Engineer for approval.

Weather limitations applicable to asphalt (Chapter 9) or coarse slurry and microsurfacing as per Clause A10.1.3.2 of Chapter 10 shall apply.
A8.4.3.2 Nominal rates for rut and depression correction

Nominal rates for tender purposes shall be in accordance with Table A8.4.3-1.

Table A8.4.3-1: Nominal rates for rut and depression correction
Component Nominal rate
Bond coat for asphalt 0,5 l/m2
Emulsion content for the coarse slurry 210 l/m3
Emulsion content for the microsurfacing 180 l/m3
Active filler content of the slurry and microsurfacing 1,65 kg/m3

All specifications for rut and depression correction addressed in this section shall apply.
The selection of the appropriate materials, equipment and methods shall be the responsibility of the Contractor, based on good practice
guidelines. The Contractor shall submit all designs to the Engineer for approval.
A8.4.5 MATERIALS
Materials and references to requirements are as follows:
Table A8.4.5-1: Specifications for rut and depression correction materials
Component Binder Aggregate
Asphalt materials: Refer to Chapter 9 As specified As specified
Coarse slurry Clause A10.1.5.4 in Chapter 10 Clause A10.1.5.17 a) in Chapter 10 for Type 1 or Type 2
Microsurfacing Clause A10.1.5.5 in Chapter 10 Clause A10.1.5.18 in Chapter 10 for Type 2 or Type 3

A8.4.6.1 Asphalt (Hot or cold applied)
The requirements as specified in Chapter 9 or Agrèment SA Certification shall apply as relevant.
A8.4.6.2 Microsurfacing and coarse slurry

The requirements as specified in Clauses A10.1.6.11 and A10.1.6.12 of Chapter 10 shall apply.

A8.4.7.1 Continuous graded asphalt
The asphalt shall be produced, transported, placed and compacted as specified in Chapter 9, as applicable. The paver shall be so adjusted that
the straight-edge blade will screed off any high spots on the existing surface and the asphalt will therefore only be placed only in depressions.
Where high spots have been planed down, the straight-edge blade shall nevertheless comply with the specified standards for evenness. Where
the required asphalt thickness exceeds 25 mm at any position, no hand placement shall be allowed, unless specified in the Contract
Documentation. Such sections of the screed shall be placed in more than one layer at thicknesses in accordance with the instructions of the
Engineer.
Where the surface of the screed breaks up, the screed shall be removed and replaced, all at the cost of the Contractor.
A8.4.7.2 Microsurfacing
The mixing and application of the microsurfacing shall be done by a mixer designed to provide a rapid mixing time, and sufficient agitation within
the spreading system to prevent segregation or premature hardening.
The appropriate workability measured by the flow (Consistency test: ASTM 3910) shall be verified during the first application and recorded as part
of a method statement.
A8.4.7.3 Coarse slurry

The mixing and application of the coarse slurry shall be done by a continuous slurry machine or if specified in the Contract documentation by
appropriate and approved equipment.
The appropriate workability measured by the flow (Consistency test: ASTM 3910) shall be verified during the first application and recorded as part
of a method statement.

The road shall be left open to traffic before further surface treatment work is carried out for such period as defined in Clause A10.1.3.6 of Chapter
10 or until such time that the representative corrected ball penetration value (SANS 3001-BT10), at the expected operating road surface
temperature (Refer SABITA Manual 40), reduces to less than 2,0 mm.

A8.4.8 WORKMANSHIP
When continuous graded asphalt or coarse slurry is used for rut filling, the completed screed shall not deviate by more than 6,0 mm from the
bottom edge of a 3,0 m straight- edge placed in any direction.
Where microsurfacing is used:
• The applied thickness of the microsurfacing, before compaction, shall be 20-25 % more than the depression/rut to be filled.
• The formulation of the product shall be such that complete curing will take place within a maximum of 4 hours, regardless of the climatic
conditions during construction, to allow opening to traffic.
• Representative corrected ball penetration value (SANS 3001-BT10), at the expected operating road surface temperature (Refer SABITA
Manual 40), shall reduce to less than 2,0 mm within a period of 4 weeks.

B8.4 RUT AND/OR DEPRESSION CORRECTION
CONTENTS
B8.4.1 SCOPE
B8.4.2 DEFINITIONS
B8.4.3 GENERAL
B8.4.5 MATERIALS
B8.4.8 WORKMANSHIP
B8.4.1 SCOPE
B8.4.2 DEFINITIONS
Definitions as provided in Clause A8.4.2 shall apply.
B8.4.3 GENERAL

B8.4.5 MATERIALS

Where reference is made in Part A to appropriate or approved equipment, the use of light equipment shall be evaluated during trial sections.

B8.4.8 WORKMANSHIP

C8.4 RUT AND/OR DEPRESSION CORRECTION
(i) Preamble
km.
C8.4.1 Rut and/or Depression correction (screeding)
C8.4.1.1 Bond coat using 50 % diluted stable grade bitumen emulsion litre (ℓ)
C8.4.1.2 Correction material
(a) Continuously-graded asphalt (State Nominal maximum aggregate size and binder type) ton (t)
(b) Semi-gap graded asphalt (State Nominal maximum aggregate size and binder type) ton (t)
(c) Cold applied asphalt (Agrèment SA certified for specific class as specified) ton (t)
(d) Coarse slurry (state aggregate grade and emulsion type) cubic metre (m³)
(e) Microsurfacing (state aggregate grade and binder type) cubic metre (m³)
The unit of measurement for the bond coat shall be the litre of emulsion applied, measured at spraying temperature. The unit of measurement for
asphalt shall be the ton of asphalt placed according to the specifications.
The of measurement for slurry and microsurfacing shall be the cubic metre of saturated fine aggregate used, measured as described in item
C10.1.20 of Chapter 10.
The tendered rate for asphalt shall include full compensation for procuring, furnishing and mixing all the materials, for placing the asphalt and for all
transport and other incidentals necessary for completing the work as specified.
The tendered rate for slurry and microsurfacing shall include full compensation for all materials, equipment and labour for producing and applying
the slurry, irrespective of the number of applications required to attain the required thickness.

D8.4 RUT AND/OR DEPRESSION CORRECTION
CONTENTS
D8.4.1 SCOPE
D8.4.2 GENERAL
D8.4.1 SCOPE
D8.4.2 GENERAL









8.5 STANDARD CRACK SEALING
CONTENTS
A8.5.1 SCOPE
A8.5.2 DEFINITIONS
A8.5.3 GENERAL
A8.5.5 MATERIALS
A8.5.8 WORKMANSHIP

A8.5 STANDARD CRACK SEALING

A8.5.1 SCOPE
This Section covers the work in connection with standard crack sealing before resurfacing or as treatment of defects.
A8.5.2 DEFINITIONS
Standard crack sealing - refers to the sealing of singular line cracks, such as longitudinal cracks, transvers cracks and large block cracks, using
cold or hot modified binders.
A8.5.3 GENERAL
The types of cracks to be treated shall be specified in the Contract Documentation. The Engineer shall instruct the Contractor regarding the type of
treatment to be used in the various cases.

Cracks shall be sealed only when the temperature of the road surface exceeds 10°C. Crack sealing may not be done within 3 days after rain has
fallen on the site.
Crack sealing shall not take place when the conditions are excessively windy or dusty.
A8.5.3.2 Traffic limitations

Unless specified differently in the Contract Documentation, no crack sealing shall be allowed before 09:00 and after 15:00.

All specifications for crack sealing addressed in this section shall apply.
The selection of the appropriate materials, equipment and methods shall be based on good practice guidelines. If the Contractor proposes a
proprietary product, it shall be certified by an independent certification agency.

A8.5.5 MATERIALS
A8.5.5.1 Herbicide
Herbicide shall be a non-selective herbicide approved by the Engineer.
A8.5.5.2 Bitumen
a) Primer for sealing cracks
The primer shall be an invert bitumen emulsion complying with SANS 4001 – BT5.
b) Modified binder crack sealant
The classification of modified binders for crack sealing, minimum required properties and requirements for short term handing and application,
shall be in accordance with the latest publication of TG1.
The binders to be used for the sealing of cracks shall be C-E1, CC-E1, C-R1 or C-R2 modified binder crack sealants as listed in the Pricing
Schedule.
c) Aggregate
Where so instructed, blinding material shall consist of crusher sand or river sand, with 100 % passing the 7,1 mm sieve and not more than 10 %
passing the 2,0 mm sieve. The aggregate shall be clean, hard and free from excessive dust and shall contain no clay, loam or other deleterious
matter.

A8.5.6.1 Equipment for crack-sealing
The Contractor shall provide the following equipment for crack sealing:
a) Blowing out cracks
A mobile compressor capable of discharging at least 3,0 m³/min compressed air at 650 kPa pressure. The compressed air shall be free of water, oil
and other deleterious matter that may adversely affect the bond between the sealant and the cracks. The compressor shall be free of oil and diesel
leaks.
A lance shall be used to direct the force of the air into the cracks and must be manoeuvrable enough to follow the path of the crack accurately.
If hot air is specified, the compressed air must be heated by a hot air lance capable of achieving a temperature of 300°C in the combustion
chamber.
b) Prime injector
A special prime injector for injecting prime into open cracks using compressed air propulsion shall be used. Essentially the equipment shall consist of a
blowpipe with nozzle to direct the jet of compressed air into the cracks, a venturi or similar device shall be fitted to the blow pipe for sucking in prime
from the storage vessel. A suitable throttling valve shall be fitted on the prime supply line to adjust the prime flow, i.e. to adjust the compressed air to
prime ratio.
The injectors, blowpipes, storage vessel interconnecting piping, inter alia, shall all be capable of safely withstanding the pressure generated by the
compressors. Design sketches of the equipment shall be submitted to the Engineer for approval.
c) Sealant applicator
The sealant shall be applied through an applicator manufactured specifically for this purpose. Essentially the equipment for the hot sealant shall
consist of a mobile vessel capable of heating the sealant to the required application temperature by indirect heat and controlled by a thermostat to
prevent overheating. A calibrated thermometer shall be fitted in an accessible position to accurately monitor the sealant temperature in the tank.
Only pumps which can deliver the sealant into the crack in a controlled manner shall be used.
The sealant shall only be applied with pressure type application equipment to ensure that the cracks are filled rather than covered. The Contractor
shall ensure that all equipment is kept clean so as to prevent blockages and resultant poor workmanship.
d) Roller
Where required, a vibratory steel-wheeled roller of between 2 and 4 tons mass with an adjustable amplitude and frequency of vibration shall be
utilised to flatten out any ridges.
e) Other equipment
All equipment shall be suitable for the specified use and working areas and shall be capable of obtaining the specified results.

The cracks shall be blown out with heated (“hot air lance”) or cold compressed air, according to the method specified in the Contract
Documentation. All dirt, grit and other base or foreign matter shall be blown out and be removed from the cracks and road surface.
A supply of approved herbicide, diluted in accordance with the manufacturers recommendations, shall be prepared. The solution shall be sprayed
into the cracks on the road surface where required by means of rucksack type of sprayers and allowed to dry.
If required in the Contract Documentation, the cracks shall be pre-treated with a specified primer.

Where, in accordance with the Contract Documentation, the cracks are to be rolled, the Contractor shall treat the cracks as follows:
• The cracks shall be cleaned and herbicides applied, if specified.
• The surface shall be heated in an approved manner along the full length of the crack and over a width of 250 mm on each side of the
crack and then rolled with approved rollers until an even surface has been obtained.
A8.5.7.2 Linear cracks smaller than 3,0 mm

No line cracks smaller than 3,0 mm width shall be sealed unless so ordered by the Engineer.
A8.5.7.3 Linear cracks of 3,0 mm and wider

Cracks shall first be cleaned before the crack is sealed. The specified sealant shall be forced into the cracks by means of the specified sealant
applicator. The Contractor shall note that a single application of crack sealant might not be sufficient and that the application might have to be
repeated.

The road shall not be opened to construction, or public traffic, until the binder has hardened sufficiently to prevent any pickup or damage of the
sealant or sand blinding layer.
A8.5.8 WORKMANSHIP
The Contractor shall ensure that the injected prime and sealant mixture actually penetrates the crack and does not merely cover the crack in the
form of a bandage. All excess sealant on the road surface wider than 30 mm on each side of the crack shall be removed and shall not be paid for.

B8.5 STANDARD CRACK SEALING
CONTENTS
B8.5.1 SCOPE
B8.5.2 DEFINITIONS
B8.5.3 GENERAL
B8.5.5 MATERIALS
B8.5.8 WORKMANSHIP
B8.5.1 SCOPE
B8.5.2 DEFINITIONS
B8.5.3 GENERAL

B8.5.5 MATERIALS


B8.5.8 WORKMANSHIP

C8.5 STANDARD CRACK SEALING
(i) Preamble
km.
C8.5.1 Standard crack sealing
C8.5.1.1 Cleaning cracks
(a) Cleaning crack with cold compressed air metre (m)
(b) Cleaning crack with hot compressed air metre (m)
C8.5.1.2 Applying herbicides for sealing cracks litre (ℓ)
C8.5.1.3 Priming (indicate primer) litre (ℓ)
C8.5.1.4 Sealing the cracks
(a) Sealing using (State crack sealant) litre (ℓ)
C8.5.1.5 Heating of surface before rolling metre (m)
C8.5.1.6 Rolling the cracks metre (m)
The tendered rates shall include full compensation for treating the crack as specified
Where cracks must be heated and/or rolled, the unit of measurement shall be a metre of crack heated/rolled.

D8.5 STANDARD CRACK SEALING
CONTENTS
D8.5.1 SCOPE
D8.5.2 GENERAL
D8.5.1 SCOPE
D8.5.2 GENERAL









8.6 GEOSYNTHETIC CRACK SEALING
CONTENTS
A8.6.1 SCOPE
A8.6.2 DEFINITIONS
A8.6.3 GENERAL
A8.6.5 MATERIALS
A8.6.8 WORKMANSHIP

A8.6 GEOSYNTHETIC CRACK SEALING

A8.6.1 SCOPE
This Section covers the work in connection with geosynthetic crack sealing before resurfacing or treatment of defects.
A8.6.2 DEFINITIONS
Geosynthetic crack sealing - refers to the application of emulsion and a geosynthetic fabric over a cracked area, with or without a sand blinding
layer.
A8.6.3 GENERAL
The types of cracks to be treated with geosynthetic shall be specified in the Contract Documentation. The Engineer shall instruct the Contractor
regarding the degree (width) and types of cracks to be treated.

Cracks shall be sealed only when the temperature of the road surface exceeds 10°C. Crack sealing may not be done within 3 days after rain has
fallen on the site, unless otherwise instructed by the Engineer.

All specifications for crack sealing addressed in this Section shall apply.
The selection of the appropriate materials, equipment and methods shall be based on good practice guidelines.
A8.6.5 MATERIALS
A8.6.5.1 Bituminous binder
The bituminous binder shall be one of the following listed in Table A8.6.5-1, and as prescribed in the Contract Documentation:
Table A8.6.5-1: Bituminous binder for geosynthetic crack sealing
Bituminous binder for geosynthetic crack sealing Specification
Cationic bitumen emulsion (solvents omitted) SANS 4001 – BT4
SC-E1(t) - (solvents omitted) TG1
Other appropriate product Certified by independent certification agency

A8.6.5.2 Geosynthetic fabric
The geosynthetic shall be a non-woven geosynthetic fabric, double needle punched with properties as specified in Table A10.1.5-10 of Chapter 10.
A8.6.5.3 Aggregate
Aggregate shall comply with Clause A10.1.5.12 of Chapter 10 for sand seals.

The Contractor shall provide the following equipment:
• Suitable hand applicator for emulsion application
• Pneumatic-tyred roller
• Other hand equipment suitable for the intended use and working areas to obtain the specified final product.

The cracks and surrounding surface shall be cleaned using compressed air and sweeping the area with hand brooms. The exact area where the
geosynthetic should be applied shall be marked out. A tack coat of the specified bitumen emulsion shall be applied at a spray rate of 0,8 l/m² by
means of a hand applicator. The geosynthetic shall then be applied to the wet tack coat by hand and rolled with a suitable roller to ensure
satisfactory bonding between the geosynthetic and the road surface. All wrinkles in the geosynthetic shall be smoothed out. The geosynthetic is
then saturated by applying a final coat of the specified bitumen emulsion by hand at 1,2 l/m² which is spread out with a squeegee. The second
application of the emulsion may be diluted with water to aid the saturation of the geosynthetic, if required or ordered by the Engineer. A layer of
sand or Grit as specified in Clause A10.1.5.12 of Chapter 10, not more than 5,0 mm thick, shall then be evenly applied using shovels and
appropriate spreading tools.

Geosynthetic patches shall be opened to traffic as soon as the emulsion has cured completely.
A8.6.8 WORKMANSHIP
The geosynthetic patch shall have a neat appearance without excess binder extending further than 30 mm from the geosynthetic patch edge.

B8.6 GEOSYNTHETIC CRACK SEALING
CONTENTS
B8.6.1 SCOPE
B8.6.2 DEFINITIONS
B8.6.3 GENERAL
B8.6.5 MATERIALS
B8.6.8 WORKMANSHIP
B8.6.1 SCOPE
B8.6.2 DEFINITIONS
B8.6.3 GENERAL

B8.6.5 MATERIALS

All specifications under this heading of Part A shall apply, except for the pneumatic-tyred roller, which could be replaced with a pedestrian roller.

B8.6.8 WORKMANSHIP

C8.6 GEOSYNTHETIC CRACK SEALING
(i) Preamble
km.
C8.6.1 Geosynthetic crack sealing
C8.6.1.1 Sealing cracks with 200 mm wide geosynthetic (specify type of emulsion) metre (m)
C8.6.1.2 Sealing cracks with geosynthetic over areas (specify type of emulsion) square metre (m²)
The unit of measurement for the 200 mm wide geosynthetic shall be the linear metre crack sealed with the geosynthetic as specified in Clause
A8.6.5.2.
The unit of measurement for the area geosynthetic crack sealing shall be the square metre crack sealed with the geosynthetic as specified.
The tendered rate shall include full compensation for procuring and supplying all materials, labour, transport and other incidentals required to
complete the work in accordance with the specifications.

D8.6 GEOSYNTHETIC CRACK SEALING
CONTENTS
D8.6.1 SCOPE
D8.6.2 GENERAL
D8.6.1 SCOPE
D8.6.2 GENERAL









8.7 PLANING
CONTENTS
A8.7.1 SCOPE
A8.7.2 DEFINITIONS
A8.7.3 GENERAL
A8.7.5 MATERIALS
A8.7.8 WORKMANSHIP

A8.7 PLANING
A8.7.1 SCOPE
This Section covers the work in connection with planing before resurfacing.
A8.7.2 DEFINITIONS
Planing in the context of this Chapter refers to level correction where the road surface is uneven and where depressions, humps or small grooves
occur as a result of deformation of the pavement layers not due to structural failure of the pavement or the removal or surface irregularities through
precision milling to a specified depth, to obtain a clean and regular running surface.
A8.7.3 GENERAL
The work involves the planing down of high spots or ridges in the existing bituminous surfacing in accordance with the specified level or thickness
requirements.

Not applicable.
A8.7.5 MATERIALS
The bituminous binder for the fog spray, where so specified, shall be anionic bitumen emulsion complying with SANS 4001 – BT3 diluted in
accordance with best practice guidelines.

A8.7.6.1 Planing machine
The machine shall be of such a design with an appropriate drum configuration which will be suitable for planing the existing surfacing, with level
control, in order to remove any irregularities without tearing or disturbing the remaining layer. The final texture shall be as smooth and even as
possible without any longitudinal grooves in excess of 1,0 mm.
Before planing may start, the Contractor shall demonstrate to the Engineer that the machine is capable of executing the work in accordance with

Planing shall be done with an approved planing machine. The full width of the road or sections of the road may be planed, depending on the
instructions of the Engineer or shown on the drawings.
Planing deeper than 25 mm shall be classified as milling and payment shall be made under items C4.3.6 or C4.3.7 of Chapter 4.
Material planed off shall be transported to stockpiles for recycling or to approved spoil sites, as specified.
Material removed beyond the specified dimensions shall not be paid for, and repairs of such affected areas shall be to the satisfaction of the
Engineer and at the Contractor’s own cost.
After the planing operation has been completed and the area broomed, the planed surface, or if so directed by the Engineer, the entire levelled
surface, shall be sprayed with a diluted anionic emulsion (50/50) which has been further diluted if necessary in accordance with the instructions of
the Engineer at a rate of application to be determined by the Engineer. After complete curing of the emulsion, the area shall be rolled with
pneumatic-tyred rollers.
Depressions over which the planning machine has moved without touching the surface and which fall outside the specified smoothness
requirements, shall be filled in as specified or, if so instructed by the Engineer, a screed shall be placed as specified in Section A8.4.

The treated surface shall only be opened to traffic when the emulsion has completely cured, and when instructed by the Engineer.
A8.7.8 WORKMANSHIP
The planed surface shall be even without any ridges or steps between the longitudinal cuts. Where planning is required over only a portion of the
road width, the edge of the planned section shall be vertical and straight.
Upon completion, the entire treated surface shall be tested for levelness and unless otherwise specified in the Contract Documentation, the surface
shall not deviate by more than 5,0 mm from the bottom edge of the 3,0 m straight-edge placed in any direction.

B8.7 PLANING
CONTENTS
B8.7.1 SCOPE
B8.7.2 DEFINITIONS
B8.7.3 GENERAL
B8.7.5 MATERIALS
B8.7.8 WORKMANSHIP
B8.7.1 SCOPE
Except for application of the fog spray, if required, this activity is not suitable for labour enhanced work.
B8.7.2 DEFINITIONS
B8.7.3 GENERAL
Application of the fog spray shall be executed in such a way as to maximise labour.

B8.7.5 MATERIALS


B8.7.8 WORKMANSHIP

C8.7 PLANING
(i) Preamble
km.
specifications.
Planing deeper than 25mm A8.7.7.1 C4.3.6 or C4.3.7 of Chapter 4
Placing of a screed A8.7.7.1 C8.4.1 – item C8.4.1.2 of Chapter 8

C8.7.1 Planing
C8.7.1.1 Planing of road surface (Indicate thickness in mm) square metre (m²)
C8.7.1.2 Fog spraying on planned surfaces litre (ℓ)
C8.7.1.3 Hand spraying litre (ℓ)
C8.7.1.4 Spraying with mechanical equipment litre (ℓ)
C8.7.1.5 Rolling the planed surface roller passes (m²-pass)

The unit of measurement shall be a square metre of road surface or concrete bridge decks planed in accordance with the specifications.
The tendered rate shall include full compensation for planing, for obtaining the required surface regularity to a maximum depth of 25 mm,
collecting, loading and removing the planed material over a haul distance of 1,0 km, for all plant movement over the site as instructed by the
Engineer and for providing planing and other equipment, labour, supervision and incidentals for completing the work in accordance with the
specifications, including filling up irregularities caused by the Contractor. Any planing deeper than nominal 25 mm shall be classified as milling.
The unit of measurement shall be a litre of diluted 60 % anionic emulsion (50/50) sprayed on planed surfaces on the instruction of the Engineer.
The tendered rate shall include full compensation for fog spraying on planed surfaces complete as specified.

The unit of measurement for rolling of planed surfaces shall be a square metre of roller-pass with an approved pneumatic roller on planed
surfaces as may be directed by the Engineer.
The tendered rate shall include full compensation for the rolling of planed surface complete as specified.
Where a screed is placed, payment shall be made under item C8.4.1.2.

D8.7 PLANING
CONTENTS
D8.7.1 SCOPE
D8.7.2 GENERAL
D8.7.1 SCOPE
D8.7.2 GENERAL









8.8 PATCHING AND EDGE BREAK REPAIR
CONTENTS
A8.8.1 SCOPE
A8.8.2 DEFINITIONS
A8.8.3 GENERAL
A8.8.5 MATERIALS
A8.8.8 WORKMANSHIP

A8.8 PATCHING AND EDGE BREAK REPAIR

A8.8.1 SCOPE
This Section covers the work in connection with patching and edge break repair before surfacing or treatment of defects.
A8.8.2 DEFINITIONS
Structural patching - involves excavating existing failed areas and reconstructing the pavement layers, with specified pavement material.
Surfacing patching - involves the repair of only the failed surfacing layer (seal or asphalt) exposing but not affecting the underlying layer.
Edgebreak repair - involves repairing the edges of the paved area so that it lines up with the true edge of the original road or with such other edge
as may be required. Work could include excavation of pavement layers and backfilling with suitable material and if specified, sealing the joint with
a geosynthetic strip. Any excavation and backfilling extending into the wheel path shall be measured under patching.
A8.8.3 GENERAL
This Section covers the patching of existing pavement layers and surfacing, as well as repairing of edge breaks, prior to any resealing or
resurfacing. Extra overcompensation for work in restricted areas shall not be applicable to any patching and repairing edge breaks.

All specifications for patching and edge break repair addressed in this Section shall apply.
The selection of the appropriate materials, equipment and methods shall be based on good practice guidelines. The design of asphalt mixes and
bituminous stabilised materials (BSM) shall be the responsibility of the Contractor and shall be undertaken in accordance with the latest version of
TRH8 (Design of Asphalt Mixes) as published by COTO, or Technical Guideline 2 (TG2 – Design of Bituminous Stabilised Material) as published by
the Asphalt Academy SA, and shall be submitted to the Engineer for acceptance.
A8.8.5 MATERIALS
A8.8.5.1 Herbicide
Herbicide shall be a non-selective herbicide.

A8.8.5.2 Bituminous binder for priming
The bituminous binder for priming the excavated area shall be one of the following as listed in Table A8.8.5-1 and as specified in the Contract
Documentation.
Table A8.8.5-1: Bituminous binder for priming the excavated area
Bituminous binder for priming the excavated area Specification
Anionic bitumen emulsion complying SANS 4001 – BT3
Cationic bitumen emulsion SANS 4001 – BT4
Invert bitumen emulsion SANS 4001 – BT5
Other appropriate product Certified by independent certification agency
A8.8.5.3 Backfill material

The backfill material shall be one of the following as listed in Table A8.8.5-2 and as specified in the Contract Documentation. The properties of the
material used for backfilling shall conform to all the requirements as prescribed in the relevant Chapters in this document as listed, or in the
Table A8.8.5-2: Backfill material
Backfill material Specification
Granular material of G4 quality Chapter 4
Crushed stone of G1, G2 or G3 Chapter 4
Cement treated material of C4 Chapter 4
BSM1 or BSM2 Chapter 4
Hot-mix asphalt (continuous or semi-gap graded as stated in the Pricing Chapter 9
Schedule)
Cold-mix asphalt: certified by Agrèment SA as a minimum of Class 2 Chapter 9
type
Coarse slurry Contract Documentation

All equipment shall be suitable for the intended use and working areas and shall be capable of obtaining the specified results.
Only approved cutting or sawing equipment may be used for cutting or sawing asphalt layers. The equipment shall be capable of cutting asphalt
layers to depths of 200 mm in one operation without fragmenting the remaining material, and in straight lines within the required tolerances.
The following items of plant and equipment shall be available and in good working order:
• Milling machine
• Saw cutting machine
• A mobile compressor
• Appropriate paving breakers
• Manually-operated pneumatic compactors as appropriate for the encountered situation
• Appropriate concrete mixers
• A vibratory roller with an adjustable amplitude and frequency of vibration
• Hand tools

A8.8.7.1 Patching
The excavation and backfilling of all patching work, complete as specified for a patch, shall be carried out and completed on the same day when
under traffic. When the portion of road being patched is temporarily closed, structural patches excluding the wearing course, shall still be
completed on the same day or as detailed in the Contract Documentation
a) Demarcation
The Contractor shall give at least four (4) calendar days’ notice to the Engineer of the intention to commence with repair work of any nature on any
specific section of the road, so that there is sufficient time to demarcate the areas to be patched.
The Engineer shall demarcate any failed areas to be repaired, which may vary in size and number from that estimated at design and tender stage
and shall instruct the Contractor regarding the repair work to be done. The Contract Documentation shall specify the various types of patching
expected to be done for the various failed areas for the project. Each demarcated area shall be cross-referenced to one of the repair types.

In addition to his specified responsibilities for the accommodation of traffic, the Contractor shall also be responsible for traffic accommodation
during the demarcation work.
b) Excavating pavement material
The patching area shall have a neat rectangular shape, unless otherwise instructed by the Engineer. The existing material shall be excavated and
removed to the full depth specified in the Contract documentation or as instructed by the Engineer. Asphalt layers and surfacing shall be cut with
approved sawing equipment.
Excavation for structural patching in granular material by hand shall be done with side slopes of approximately 60 degrees to the horizontal.
Unless specifically otherwise specified, the Contractor may choose to carry out the excavation in the existing pavement layers either by hand with
the aid of jackhammers and saw cutting machines, or with an appropriate milling machine.
Front end loaders or TLB’s may not be used for breaking up and excavating the existing pavement, but may be used to assist with the loading of
the excavated material into trucks
Excavated material from each pavement layer shall be placed in separate stockpiles adjacent to the patch if to be re-used. The stockpiled material
shall be re-used or spoiled in an approved manner in accordance with the Engineer’s instructions.
After completion of the excavation to the specified depth, the Engineer shall be afforded the opportunity to approve the excavation. Where
required, the floor of the excavation shall be compacted to the specified density for the layer concerned.
c) Backfilling excavations
Excavations for structural patching and surfacing patching shall be backfilled with compliant pavement material as specified in the Contract
Documentation. The backfilling shall be compacted to the specified density and finished to the required levels or finished to match the existing
levels of the surrounding surface. The level tolerances for patches are specified in Clause A8.8.8.1.
Where backfilling material consists of any bituminous based products, the floor and sides of the prepared excavation shall be treated with a bond
coat consisting of a diluted stable grade anionic bitumen emulsion (50/50) and applied at a nominal rate 0,5 l/m². The bond coat shall be applied
by means of an approved pressurised sprayer, hand sprayer or paint brush, or a combination thereof, dependant on the specific dimensions of the
patch.
Cement or bituminous stabilized materials shall be mixed in concrete mixers or by other approved equipment. Placing concrete in patches shall
not be permitted.
A8.8.7.2 Edgebreak repairs

Where the existing edge of the surfacing is sound and undamaged, but the required surfacing width is exceeded by more than 50 mm, the excess
surfacing shall be cut back by saw cutting and trimming, parallel to the centre line of the road, to the required width. Where the edge of the
surfacing is fragmented or where the surfacing is narrower than the required width, it shall be cut back to a line along which a sound and uniform
edge can be obtained, without reducing the shoulder or driving lane by more than 100 mm.
Where the surfacing, after having been cut back, is narrower than the specified width, the pavement material between the cut edge and the
specified surfacing edge shall be excavated to a depth of 60 mm below the final road surface, or until firm material is found. The edges shall then
be built up with asphalt or other material as specified in the Contract Documentation. All exposed surfaces resulting from any cutting and
excavations shall be treated with a bituminous bond coat as described in Clause A8.8.7.1c) prior to reinstatement.
After the edge is built up and if prescribed in the Contract Documentation a geosynthetic strip wide enough to overlap the joint of the repair shall
be placed in accordance with Clause A8.6.7.1.

Unless otherwise instructed, in writing, by the Engineer, the excavation, backfilling and all patching work, complete as specified, for any patch
shall be carried out and completed on the same day. Traffic accommodation and workman safety measures shall be as prescribed in the Contract
Documentation.
A8.8.8 WORKMANSHIP
A8.8.8.1 Tolerances
The backfilling shall be compacted to the appropriate thickness, density and level per layer specified in other relevant sections of this document or as
The final riding surface on any particular point on patches and repaired edge-breaks shall not deviate more than 5,0 mm from the bottom of a 3,0
m long straight edge.
Edge repairs shall be true to line with a maximum deviation of 20 mm from the specified edge line.
A8.8.8.2 Testing
The Engineer shall carry out routine inspections and conduct routine tests to determine whether the quality of material and workmanship provided
comply with the requirements as specified in this Section. Any test results and measurements shall be assessed in accordance with the provisions
of Chapter 20, as applicable.

B8.8 PATCHING AND EDGE BREAK REPAIR
CONTENTS
B8.8.1 SCOPE
B8.8.2 DEFINITIONS
B8.8.3 GENERAL
B8.8.5 MATERIALS
B8.8.8 WORKMANSHIP
B8.8.1 SCOPE
B8.8.2 DEFINITIONS
B8.8.3 GENERAL

B8.8.5 MATERIALS


B8.8.8 WORKMANSHIP

C8.8 PATCHING AND EDGE BREAK REPAIR
(i) Preamble
km.
specifications.
Milling (where specified in the Contract Documentation) C8.8.2 C4.3.6 or C4.3.7 of Chapter 4

C8.8.1 Saw cutting pavement layers for patching
C8.8.1.1 Asphalt or bituminous surfacing to an average depth
(a) Not exceeding 50 mm metre (m)
(b) Exceeding 50 mm but not exceeding 100 mm metre (m)
(c) Exceeding 100 mm metre (m)
C8.8.1.2 Cemented pavement layers to an average depth
(b) Exceeding 100 mm but not exceeding 200 mm metre (m)
C8.8.1.3 Granular layers to an average depth
(b) Not exceeding 200 mm metre (m)

The unit of measurement shall be the metre of sawcut. The length in each depth range shall be measured and paid separately.
The tendered rate shall include full compensation for all plant, equipment, labour, supervision, materials, transport and for all incidentals for
sawing the asphalt and the cemented pavement layers, complete as specified and prescribed by the Engineer, and also for work in restricted
areas. The rate shall also include for any haul to an approved spoil site if so required.
C8.8.2 Excavation in existing pavements for patching (non-milling)
C8.8.2.1 Asphalt layers

cubic metre (m³)
(a) Not exceeding 10 m2 including for edge repairs wider than 250 mm
cubic metre (m³)
(b) Exceeding 10 m² but not exceeding 50 m² including for edge repairs wider than 250 mm
cubic metre (m³)
(c) Exceeding 50 m² up to 100 m² including for edge repairs wider than 250 mm
cubic metre (m³)
(d) Exceeding 100 m2
C8.8.2.2 Cemented layers

cubic metre (m³)
(a) Not exceeding 10 m2 including for edge repairs wider than 250 mm
cubic metre (m³)
(b) Exceeding 10 m² but not exceeding 50 m² including for edge repairs wider than 250 mm
cubic metre (m³)
(c) Exceeding 50 m² up to 100 m² including for edge repairs wider than 250 mm
cubic metre (m³)
(d) Exceeding 100 m2
C8.8.2.3 Other layers (specify type)
(a) Not exceeding 10 m2 including for edge repairs wider than 250 mm cubic metre (m³)
(b) Exceeding 10 m² but not exceeding 50 m² including for edge repairs wider than 250 mm cubic metre (m³)
(c) Exceeding 50 m² up to 100 m² including for edge repairs wider than 250 mm cubic metre (m³)
(d) Exceeding 100 m2 cubic metre (m³)

All excavations in items C8.8.2.1(a), C8.8.2.2(a) and C8.8.2.3(a) shall be done by hand.
Distinction shall be made between excavation and milling of materials. In addition to this separate pay items apply to asphalt milling dependent
on the ownership of the millings as specified in the Contract Documentation. Milling, where specified shall be measured and paid for under items
C4.3.6 or C4.3.7 of Chapter 4, if specified in the Contract Documentation. If milling for patch excavation is not specified, excavation shall be
measured and paid for under item C8.8.2.
The unit of measurement shall be a cubic metre of material excavated from the existing pavement. The quantity shall be computed in accordance
with the authorised dimensions of the excavation.
The tendered rate shall include full compensation for demarcating the excavation, excavating the material, placing the excavated material in
temporary stockpiles, spoiling of material in the stockpiles where ordered by the Engineer, including haul over a haul distance of 1,0 km, complete
as specified, and also for work in restricted areas.
Payment shall distinguish between the different types of pavement material excavated.
C8.8.3 Compacting the floor of excavations for patching (specify density) square metre (m²)
The unit of measurement shall be a square metre of excavation floor compacted on the instruction of the Engineer, and the quantity shall be
computed in accordance with the authorized dimensions of the excavation floor.
The tendered rate shall include full compensation for compacting the floor of excavations complete as specified, and also for work in restricted
areas. Payment shall not distinguish between the various methods of compaction or various compaction requirements.
C8.8.4 Backfilling of excavations for patching with:

C8.8.4.1 Chemically stabilized pavement material (state the pavement
material and the stabilising agent) for a patch with a surface area:


C8.8.4.2 Bitumen Stabilised Material (specify type and level of compaction) for a
patch with a surface area:
C8.8.4.3 Asphalt for a patch with a surface area (state type and density)
(a) Not exceeding 10 m2 including for edge repairs wider than 250 mm ton (t)
(b) Exceeding 10 m² but not exceeding 50 m² including for edge repairs wider than 250 mm ton (t)
(c) Exceeding 50 m² up to 100 m² including for edge repairs wider than 250 mm ton (t)
(d) Exceeding 100 m2 ton (t)
C8.8.4.4 Granular base material (state type and density) for a patch with a surface area
(a) Not exceeding 10 m2 including for edge repairs wider than 250 mm ton (t)
(b) Exceeding 10 m² but not exceeding 50 m² including for edge repairs wider than 250 mm ton (t)
(c) Exceeding 50 m² up to 100 m² including for edge repairs wider than 250 mm ton (t)
(d) Exceeding 100 m2 ton (t)
The tendered rates shall include full compensation for design of backfill material, providing all the material, irrespective of its origin, including gravel,
for all mixing, placing, compacting and finishing as specified in this Section and other appropriate Sections of the specifications, for all transport,
work in restricted areas, and also for all machinery, equipment, labour, supervision and other incidentals for executing the work as specified.
The tendered rate shall also include full compensation for the provision and application of the stabilisation agents.
C8.8.5 Geosynthetic patching
C8.8.5.1 Sealing joints with geosynthetic strips (specify width and type of emulsion) metre (m)
The tendered rate shall also include full compensation for cleaning of the road surface, supply and application of the geosynthetic strips on the
emulsion. The geosynthetic strips shall be as specified in Section A12.11 of Chapter 12.
C8.8.6 Repairing edge breaks in surfacing
C8.8.6.1 Cutting back the edges of the existing surfacing for the repairing of edge breaks metre (m)
C8.8.6.2 Prime coat (state type and rate of application) litre (ℓ)
C8.8.6.3 Reconstructing edges using:
(a) Continuously-graded hot asphalt (state type and density) ton (t)
(b) Continuously-graded cold asphalt (Agrèment SA certified -state class and density) ton (t)
(c) Bitumen Stabilised Material (state type and level of compaction) cubic metre (m³)
Item C8.8.6 shall apply only to edge breaks with an average width of 250 mm and less. Repairing wider edge breaks shall be classified as
patching.
The unit of measurement for cutting back the edges shall be a metre of pavement edge cut back and excavated as specified.
The tendered rate for cutting back the edges shall include full compensation for cutting back the edges in accordance with instructions,
excavating the material to the specified depth, removing all excavated and loose material to spoil, and compacting the surface onto which the
fresh edge shall be constructed, all in accordance with the required lines and levels.
The tendered rates shall also include full compensation for all transport, handling, labour, material, and all incidentals necessary for completing
all the work.

D8.8 PATCHING AND EDGE BREAK REPAIR
CONTENTS
D8.8.1 SCOPE
D8.8.2 GENERAL
D8.8.1 SCOPE
D8.8.2 GENERAL









8.9 REPAIR OF SURFACE DEFECTS
CONTENTS
A8.9.1 SCOPE
A8.9.2 DEFINITIONS
A8.9.3 GENERAL
A8.9.5 MATERIALS
A8.9.8 WORKMANSHIP

A8.9 REPAIR OF SURFACE DEFECTS

A8.9.1 SCOPE
This Section covers the work in connection with the repair of surface defects.
A8.9.2 DEFINITIONS
Repair of surface defects - deals specifically with repair of early bleeding areas and/or aggregate loss during the Defect Notification Period as
defined in the conditions of contract.
Repair of surfacing failures (typically delamination) is dealt with under patching in Section A8.8.
Bleeding - occurs when excess binder moves upwards relative to the aggregate and reduces the surface texture depth
Aggregate loss (ravelling) - is the loss of surfacing aggregate
A8.9.3 GENERAL
When surface defects occur within the maintenance period, the Contractor shall search and find the cause and mechanism of distress, propose
and submit an appropriate repair method, in accordance with current good practice or specifications provided in this section, to the Engineer for
approval. The proposed method/s shall include a detailed method statement, materials, construction equipment, traffic accommodation and quality
plan.
Aggregate loss of Degree 2 or more and bleeding of Degree 3 and more according to the latest revision of TMH9 Part B, occurring within the
defects liability period, as prescribed in the General Conditions of Contract, shall be repaired.
Sections of the road where severe loss of aggregate (Degree 3 or more), or bleeding (Degree 4 or 5) have occurred shall be closed to traffic by
means of the statutory required road signs.
In case of aggregate loss, all loose stones shall be removed from the road surface and disposed of at an approved spoil site. The Contractor shall
make sure that all the remaining aggregate is satisfactorily embedded into the road surface.
This work shall be effected as soon as possible after the distress occurs. However, the Contractor may not commence with the repair work without
the Engineer’s approval.
Notwithstanding the proposed method/s of treatment, the Engineer may order any seal which has not been properly constructed to be removed
and replaced. The removal of the seal shall be done so as not to damage the existing substrate. All aggregate and binder shall be removed either
by grader or by hand tools and disposed of at an approved spoil site. Any damage done to the substrate surface shall be repaired to the satisfaction
of the Engineer.

The Contractor shall assess, investigate and design appropriate remedial measures and submit his proposals to the Engineer for approval prior to
commencing any permanent repairs
A8.9.5 MATERIALS
Materials proposed and used for repair shall be appropriate materials complying with relevant referenced specifications in this document.

Construction equipment appropriate to the proposed and approved repair method shall be listed as part of the detailed method statement for repair.

A8.9.7.1 Bleeding
Bleeding shall be corrected by one or more of the methods described below or according to the method approved by the Engineer.
a) Application and rolling in of heated aggregate with, or without, softening of the existing surfacing with an approved heating
apparatus
The Engineer shall determine the size of the aggregate to be applied to the bleeding portions and for this purpose he may require ball penetration
tests to be performed on the portions in question. The nominal maximum size of aggregate shall either be 10 mm or 7,1 mm complying with the
requirements of Clause A10.1.5.10 of Chapter 10.
Trial sections shall be constructed to determine the most effective process using:
• 10 mm and 7,1 mm aggregate
• Pre-coated and unprecoated aggregate
• Heated aggregate
• Heating of the road surface
• Steel wheel and pneumatic-tyred rolling
If the binder of the existing surface has an oxidised film or if the road has been used by traffic for some time, the surface shall be softened by heating
apparatus. The heating apparatus shall be an approved type that does not expose the road surface to open flames. This work shall only commence
when the road temperature exceeds 30°C.
The aggregate, heated to 60°C at the time of application shall be applied to the surface at the rate determined by the Engineer and immediately
rolled with a flat wheeled (steel) roller as well as a pneumatic-tyred roller having a mass of at least 2t per wheel, until the aggregate is firmly
embedded. All loose aggregate not embedded shall be broomed off the road before it is opened to traffic. The road shall only be opened to traffic
if the road surface temperature has cooled off sufficiently in the opinion of the Engineer, usually in the late afternoon. When opening the road to
traffic the treated areas shall be demarcated with traffic cones and speed limit and “loose stone” signs for at least the first two days. All loose
aggregate shall be broomed off and removed at least twice per day until full adhesion of the aggregate has been achieved.
Areas where whip-off is excessive after the treatment has been completed, shall be retreated in accordance with the Engineer’s instructions.
If only one lane and/or shoulder or half the road width is to be treated the application of aggregate shall be finished in a neat line. If only half the
road width is to be treated, the application of aggregate shall be finished in a neat line on the centre line of the road.
b) Water cutting
Areas with excess binder, Degree 3 or more according to TMH9 Part B and/or insufficient macro texture, according to performance-based
specifications in Part D of this Section, shall be marked out.
Trials shall be conducted with the approved apparatus using different pressure settings and jets to obtain the target macro texture for the particular
type of seal according to Clause D10.1.6 of Chapter 10.
Before opening any rectified work to traffic, the road surface shall be properly cleaned and the waste material spoiled at an approved dump site.
c) Removal
Where very severe bleeding (Degree 4 or 5 according to TMH9 Part B) in large sections or in circumscribed smaller sections occur, the Engineer
may prescribe the removal of the seal.
In these sections the seal shall be removed from the surface of the base by means of an approved method, e.g. planing or blading. The removal
work shall be executed while the temperature of the road surface is below 15°C. If necessary, the road surface shall be cooled with water during
the execution of the work.
Only graders fitted with new blades shall be used.
The Contractor shall repair all damage to the surface of the base to the satisfaction of the Engineer, where after an asphalt surfacing or a new
seal shall be applied in accordance with the Engineer’s instructions.
A8.9.7.2 Aggregate loss

Aggregate loss during construction or within the Defects Notification Period shall be corrected, at the cost of the Contractor, by one or more of the

methods described below or according to the method approved by the Engineer.
a) Slight loss of aggregate
Slight loss of aggregate or perceived future risk thereof according to good practice guidelines and experience, shall be treated in accordance with
the requirements of the Engineer, with the aid of a cover spray. The surface to be treated shall be clean and dry and a diluted cationic spray-grade
emulsion (60/40) or diluted SC-E1 (60/40) shall be applied at a minimum rate of 0,8l/m² or such higher rate as may be approved by the Engineer.
b) Loss of aggregate: Isolated areas
(i) Single seals or upper layer of double seals
One of the following methods shall be applied:
1. Remove and replace
The areas where the remaining aggregate has to be removed from the road surface shall be demarcated by the
Engineer. The remaining aggregate in these areas shall be removed with hand-equipment. Heating apparatus as
described in Clause A8.9.7.1a) shall be used. Thereafter the areas shall be resealed as specified in Clause A10.1.7.1 of
Chapter 10.
2. Replace with smaller aggregate
Cationic spray grade emulsion or SC-E1 shall be hand applied at an approximate rate of 0,8 l/m² and dry precoated
aggregate of one nominal maximum size smaller than the stripped aggregate originally applied to fill the voids.
When the emulsion has cured properly, the area shall be rolled with a pneumatic tyre roller and a cover spray applied
using a diluted cationic spray-grade emulsion (60/40) at a rate of 0,8 l/m².
c) Loss of both layers of a double seal
(i) Remove and replace
The areas where the remaining aggregate must be removed from the road surface shall be demarcated by the Engineer. The
remaining aggregate in these areas shall be removed with hand-equipment. Heating apparatus as described in Clause A8.9.7.1a)
shall be used. Thereafter the areas shall be resealed as specified in Clause A10.1.7.1 of Chapter 10.
(ii) Application of the second aggregate layer
Cationic spray grade emulsion or SC-E1 shall be hand applied at an approximate rate of 0,8 l/m² and dry precoated aggregate
of one nominal size smaller than the initial small aggregate used to fill the voids.
When the emulsion has cured properly, the area shall be rolled with a pneumatic tyre roller and a cover spray applied using a
diluted cationic spray-grade emulsion (60 % emulsion/40 % water) at a rate of 0,8 l/m².
d) Loss of aggregate: Large area
One of the following methods shall be applied:
(i) Remove and replace
The remaining aggregate shall be bladed from the road surface as soon as possible. Following investigation regarding the
substrate conditions, the exposed area shall be resealed with binder and aggregate according to the design approved by the
Engineer.
(ii) Replace and add additional layer of small aggregate
As soon as the temperature of the road surface is within the prescribed limits as stated in Table A10.1.3-1 of Chapter 10, a spray of
cationic spray grade emulsion or SC-E1 shall be applied at the rate of 0,8 l/m² or the rate approved by the Engineer. Nozzles of the
distributor could be closed to only apply the binder only where required.
Precoated aggregate of the same size as the stripped aggregate shall be applied by a self-propelled mechanical chip spreader at
the rate determined through a trial section and rolled with a 2-4-ton steel wheel roller. When the emulsion has cured sufficiently,
the area shall be rolled with pneumatic-tyred rollers, covering the repaired areas with at least eight roller passes.
A precoated 5,0 mm aggregate complying with Clause A10.1.5.10 of Chapter 10 (Grade 3), or precoated Grit seal complying with
Clause A10.1.5.12 of Chapter 10, is then constructed over the entire road surface, using a diluted cationic spray grade emulsion
(60/40) at 0,8 l/m² and aggregate spread rate of 240 m2/m3.
(iii) Replace and add slurry texture treatment
As soon as the temperature of the road surface is within the prescribed limits, a spray of cationic spray grade emulsion or SC-E1
shall be applied at the rate specified or approved by the Engineer. Nozzles of the distributor could be closed to only apply the
binder only where required.
Precoated aggregate of the same size as the stripped aggregate shall be applied by a self-propelled mechanical chip spreader at
the rate determined through a trial section and rolled with a 2-4-ton steel wheel roller. When the emulsion has cured sufficiently,
the area shall be rolled with pneumatic-tyred rollers, covering the repaired areas with at least eight roller passes.
A fine slurry texture treatment shall then be applied by hand over the full width as specified in Section A8.3.

Repaired sections shall only be opened to traffic when the applied binder has cured sufficiently and large aggregate particles are well embedded
and the road surface is deemed safe to travel on.

A8.9.8 WORKMANSHIP
The Engineer shall undertake routine inspections and routine tests to determine whether the quality of material and workmanship provided comply
with the requirements of this Section.

B8.9 REPAIR OF SURFACE DEFECTS
CONTENTS
B8.9.1 SCOPE
B8.9.2 DEFINITIONS
B8.9.3 GENERAL
B8.9.5 MATERIALS
B8.9.8 WORKMANSHIP
B8.9.1 SCOPE
B8.9.2 DEFINITIONS
B8.9.3 GENERAL

B8.9.5 MATERIALS


B8.9.8 WORKMANSHIP

C8.9 REPAIR OF SURFACE DEFECTS
(i) Preamble
km.
9. Aggregate loss during construction or within the Defects Notification Period shall be corrected at the cost of the Contractor.
C8.9.1 Heating of the road surface
C8.9.1.1 Establishing of heating apparatus on site for softening of the road surface lump sum
C8.9.1.2 Heating of road surface square metre (m²)
The unit of measurement for the heating of the road surface is the square metre heated as specified.
Except for the provision of heating apparatus, the tendered rate for heating the road surface shall include full compensation for all equipment,
materials and labour needed for the heating of the road surface, all in accordance with the specifications.
C8.9.2 Aggregate for treatment of bleeding sections
C8.9.2.1 Heated aggregate (state size) cubic metre (m³)
C8.9.2.2 Precoating of aggregate (state type and application litre/m3) cubic metre (m³)
The unit of measurement for the provision of aggregate shall be the cubic metre of aggregate as specified.
The tendered rate shall include full compensation for furnishing the aggregate, for precoating it, if required, with a bitumen based precoating fluid,
including the furnishing of the precoating fluid, and for heating it to the specified temperature, all in accordance with the specifications and
instructions of the Engineer.
C8.9.3 Application and rolling in of heated aggregate square metre (m²)
The unit of measurement for the application and rolling in of the aggregate shall be the square metre of road treated in accordance with the
specifications and instructions of the Engineer.
The tendered rate shall include full compensation for cleaning the existing road surface, for the application of the aggregate, irrespective of the size,
with an approved chip spreader to the specified rate, for rolling in the aggregate as specified, for brooming off excessive aggregate as and when

needed, all in accordance with the specifications and instructions of the Engineer.
The tendered rate shall not include the provision of the aggregate.
C8.9.4 Trial sections for heating, application and rolling in of heated aggregate square metre (m²)
The unit of measurement shall be the square metre of trial section constructed as ordered.
The tendered rate shall include full compensation for the construction of the trial section as instructed. It shall only be paid more than once if it is
unsuccessful and the Contractor has executed all work according to the specifications and instructions.
C8.9.5 Water cutting square metre (m²)
C8.9.5.1 Establishing of water cutting equipment on site lump sum
C8.9.5.2 Water cutting of the road surface square metre (m²)
The unit of measurement for the water cutting of the road surface is the square metre of road treated in accordance with the specifications and
instructions of the Engineer.
Except for the provision of water cutting equipment, the tendered rate for water cutting of the road surface shall include full compensation for all
equipment, materials and labour needed for water cutting of the road surface, including removal of material generated to an approved spoil site, all
in accordance with the specifications.
C8.9.6 Trial sections for water cutting square metre (m²)
The tendered rate shall include full compensation for a trial section as instructed. It shall only be paid more than once if it is unsuccessful and the
Contractor has executed all work according to the specifications and instructions.

D8.9 REPAIR OF SURFACE DEFECTS
CONTENTS
D8.9.1 SCOPE
D8.9.2 GENERAL
D8.9.1 SCOPE
D8.9.2 GENERAL









South Africa
COTO
Officials


October 2020

this Draft Standard document for i ndustry use.
FOREWORD

Published by:

industry.
Document versions:
Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 9: ASPHALT LAYERS............................................................................................................................9-1
9.1 ASPHALT LAYERS ............................................................................................................................................9-1
PART C: MEASUREMENT AND PAYMENT .................................................................................................................................................. 9-22
9.1 ASPHALT LAYERS
CONTENTS
A9.1.1 SCOPE
A9.1.2 DEFINITIONS
A9.1.3 GENERAL
A9.1.5 MATERIALS
A9.1.8 WORKMANSHIP

A9.1 ASPHALT LAYERS

A9.1.1 SCOPE
This Chapter covers the following work:
All work in connection with the construction of asphalt base and surfacing layers in accordance with current good practice and any other specific
work as may be prescribed. It includes the:
- Design of the specified mix type, procuring and furnishing of aggregate, active fillers and bituminous binder, mixing at a central mixing plant,
transport, placement and compaction of the product.
- Widening of asphalt bases and surfacing, placing of asphalt in restricted areas and placing asphalt reinforcing where specified
- Recycling of asphalt by reprocessing reclaimed asphaltic materials, adding new aggregate, bituminous binders and rejuvenating agents to
obtain an asphalt mix which will comply in all respects with the standard final product requirements for a particular mix as specified.
- General provisions and requirements of Chapter 9 shall apply throughout to recycled asphalt, except where explicitly specified otherwise in
Asphalt layers constructed utilising certified products with, or without, extended performance guarantees, are covered in Part D of this Chapter.
A9.1.2 DEFINITIONS
Asphalt mix types - a mixture of aggregate, with or without active filler, and an appropriate bituminous binder proportioned in such a manner as
to produce a final product conforming to all the relevant mix, and or, performance properties as specified. Asphalt mixes are classified into two
fundamental mix types and may incorporate either standard, homogenous modified or non-homogenous (bitumen-rubber) bitumen.
a) Sand skeletal mixes - where the loads on the layer are carried by a continuous matrix of the finer aggregate fraction. There is no
meaningful contact between the individual coarse aggregate particles and only provide bulk while not compromising the continuity of
the finer fraction. Examples include:
- Semi-gap graded asphalt (AS), as further defined in Sabita Manual 35; Design and Use of Asphalt in Road Pavements
- Gap-graded asphalt (AG), as further defined in Sabita Manual 35; Design and Use of Asphalt in Road Pavements
- Fine/medium continuously graded asphalt mixes (AC), as further defined in Sabita Manual 35; Design and Use of Asphalt in Road
Pavements
- Bitumen-rubber gap-graded (BRAGG), as further defined in Sabita Manual 19; Guidelines for the design, manufacture and
construction of bitumen rubber asphalt wearing courses

b) Stone skeletal mixes - where a continuous matrix (skeleton) of coarse aggregates carries the imposed loads. In dense mixes the
spaces between the coarse aggregate fractions are filled by the finer aggregate fractions to an extent that assures that the skeleton is
not dilated, and contact between the coarser aggregate particles is maintained. In porous mixes, the spaces between the coarse
aggregates are void. Examples include:
- Coarse continuously graded (AC), as further defined in Sabita Manual 35; Design and Use of Asphalt in Road Pavements
- Stone mastic (SMA), as further defined in Sabita Manual 35; Design and Use of Asphalt in Road Pavements
- Ultra-thin friction course (UTFC)
- High modulus base (EME), as further defined in Sabita Manual 33; Design Procedure for High Modulus Asphalt (EME)
- Porous (AP), as further defined in Sabita Manual 17; Design of Porous Asphalt Mixes
- Bitumen-rubber gap graded (BRAGG), as further defined in Sabita Manual 19; Guidelines for the Design, Manufacture and
Construction of Bitumen-Rubber Asphalt Surfacings.
- Bitumen-rubber open graded (BRAOG). as further defined in Sabita Manual 17; Design of Porous Asphalt Mixes
- Proprietary mixes, such as UTFC, which have been independently certified as fit-for-purpose.
The particular mix type, and or, any additional requirements, shall be as specified in the Contract Documentation.
Asphalt mixes - produced by any of the methods below:
- Hot mix asphalt (HMA) – asphalt produced in the traditional manner at mixing and placing temperatures appropriate to the inherent
rheological properties of the binder incorporated.
- Warm mix asphalt (WMA) – as per a standard hot mix asphalt type and requirements, with the exception that an appropriate agent is
introduced to enable mixing and placement of the specific product at reduced temperatures.
- Cold mix asphalt (CA) – asphalt, generally including a proprietary agent that has been pre-mixed in a mixing plant, packaged and stored
for future applications at ambient temperatures. The specific mix, performance and application requirements of such mixes are not
prescribed in this Chapter but shall be as specified in Chapter 8, or in the Contract Documentation. Cold mix products may also be
prescribed as being fit for purpose for specific applications as certified by an approved independent certification agency.
- Recycled asphalt – as per any standard asphalt mix type, with the exception that a proportion of the mix, as may be prescribed or
otherwise, shall consist of asphalt reclaimed from existing layers and appropriately processed and included in the mixture together with
an approved rejuvenating agent if required.
- Certified asphalt mixes - asphalt mixes, such as UTFC or cold-mix products that have been certified as being fit for purpose for the
required functional, and or, structural properties as required. Such Certification Agency may be Agrément SA, or any other accredited
facility, as approved by the Employer. Such products may be constructed with, or without, extended performance guarantees, and shall
be constructed as prescribed in Part D, or any other Chapter of these specifications.
Aggregate - granular material of natural, manufactured or recycled origin used in the manufacture of asphaltic products to the specific grade/class
as defined in these specifications and the latest published version of SANS 1083, or as may be specifically specified in the Contract
Documentation:
- Course aggregate – all aggregate > 5,0 mm as further defined in the latest SANS 1083 specification for the specific class of aggregate
and nominal maximum particle size as specified.
- Nominal maximum particle size (NMPS) – designated as one sieve size larger than the largest sieve to retain a minimum of 15
percent of the aggregate particles as defined in SANS 1083.
- Fine aggregate – all aggregate fractions ≤ 5,0 mm > 0,075 mm and which may consist of clean material derived from crushing
competent parent rock, or naturally occurring sand conforming to good practice and any further specified requirements.
- Filler – material predominantly < 0,075 mm which may consist of natural rock flour, extracted bag-house fines, or a manufactured active
filler such as hydrated lime or cement.
- Reclaimed asphalt (RA) – asphalt that has been appropriately milled off existing pavement layers, as well as asphalt discarded at the
mixing plant that is crushed, screened and tested in accordance with the requirements contained in the latest version of TRH 21: Use
of Reclaimed Asphalt in the Production of Asphalt.
Bitumen - a black viscous mixture of hydrocarbons obtained as a residue from crude oil distillation and processed according to specific grade
requirements.
Cellulose fibre - a constituent, either loose or in pellet form, introduced at manufacturing stage to prevent drain-down of the binder during storage,
transporting and placing of mixes such as Stone Mix Asphalt (SMA).
Bond coat - an appropriate bituminous product applied to an existing surface, (prime, spray seal, asphalt, or concrete pavement surface), in order
to ensure adequate bonding with the underlying substrate layer.
Prime coat - an appropriate low viscosity bituminous product applied in a single application for the purposes of sealing and protecting the surface
of granular or cemented base layers. The general requirements relevant to these products are covered in Chapter 8 of this document.
A9.1.3 GENERAL
A9.1.3.1 Nominal mix proportions and application rates
a) Mix composition. The mix proportions of bituminous binder, combined aggregates and filler for the various mix types, as well as bond coat
and rolled-in chip applications, as listed in Tables A9.1.3-1 to A9.1.3-3 below, are nominal, and shall only be used for tendering purposes.
The proportions actually used shall be as determined during the mix design, trial section and assessment requirements as specified in Clause
A9.1.3.3. Any approved variation to these nominal mix proportions, and or, application rates shall be subject to an adjustment in payment,
calculated in accordance with Clause C1.1.4 of Chapter 1 and relevant to the applicable variation rates tendered for each component as
listed under Measurement and Payment.

Table A9.1.3-1: Nominal Mix Proportions of Stone Skeletal Mixes for Tender Purposes
Continuous graded base Stone Mastic Continuous Gap graded surfacing: Mixes containing
High and surfacing: Asphalt graded Bitumen-rubber: reclaimed asphalt
Modulus conventional and (SMA) surfacing:
MIX TYPE Base (EME) homogenous modified Bitumen-
bitumen rubber:
Nominal maximum Refer to Note* 2

20 14 20 14 10 14 10 20,0 14,0 20,0 14,0
particle size (mm) below and
Contract
Aggregate (%) 93.0 92.0 94,0 93,5 93,0 92,5 92,0 92,0 91,5 91,5 91,0 Documentation
Bitumen (type and
grade according to
6,0 7.0 5,0 5,5 6,0 6,5 7,0 7,0 7,5 7,5 8,0
Contract
Documentation) (%)
Active filler*1 (%) 1.0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0
Cellulose fibre (%) N/A N/A N/A N/A N/A 0,5 0,5 N/A N/A N/A N/A
*Note 1: Active filler for tender purposes shall be hydrated lime

*Note 2: The nominal proportions for mixes containing reclaimed asphalt shall be as specified in the Contract Documentation dependent on the
percentage of reclaimed asphalt or binder replacement limits specified or permitted. If no such amendments are specified, the standard nominal
mix proportions tabled above shall apply.
Table A9.1.3-2: Nominal Mix Proportions of Sand Skeletal Mixes for Tender Purposes
Continuous graded base Gap and semi-gap mixes Mixes containing reclaimed asphalt
and surfacing: standard and using standard and
homogenous modified homogenous modified
MIX TYPE bitumen bitumen
Nominal Refer to Note* 2 below and

maximum particle 20 14 10 14 10 Contract Documentation
size (mm)
Aggregate (%) 94,0 93,5 93,0 92,5 92,0

Bitumen (type and
grade according
to Contract 5,0 5,5 6,0 6,5 7,0
Documentation)
(%)
Active filler*1 (%) 1,0 1,0 1,0 1,0 1,0

*Note 2: The nominal proportions for mixes containing reclaimed asphalt shall be as specified in the Contract Documentation dependent on the
percentage of reclaimed asphalt specified or permitted. If no such amendments are specified, the standard nominal mix proportions tabled above
shall apply.
b) Bond coat and rolled-in chippings. The nominal application rates for tender purposes for asphalt bond coats and rolled-in chippings shall be
as tabled below.
Table A9.1.3-3: Nominal application rates for bond coats and rolled-in chippings
Nominal Bitumen % Filler*1 (%)
Product
application rate
Bond coat
(a) Pavement 0,55 l/m²
(b) Bridge decks 0,40 l/m²
Rolled in chippings
20 mm 8 Kg/m² 1,5 1,0
14 mm 6 Kg/m² 1,7 1,0
10 mm 4 Kg/m² 2,0 1,0

The nominal rates for tender purposes for the bond coat are based on 30 % stable grade emulsion. Nominal application rates for other bond coat
products shall be as specified in the Contract Documentation.
The actual application rate for rolled-in chippings shall be as determined and approved by the Engineer based on the relative density of the
aggregate and the target texture depth to be achieved.
A9.1.3.2 Quality Plan

Prior to commencing with any permanent works, the Contractor shall submit a Quality Plan, for acceptance by the Engineer, detailing all checks
and hold points relating to construction of the specified product.

Where so provided for under Measurement and Payment, the Contractor shall construct a trial section for each layer, and relevant mix type,
specified. The purpose of the trial is for the Contractor to demonstrate that the equipment and processes that he proposes to use will enable him
to construct the particular asphalt layer in accordance with all the specified requirements. Evaluation and monitoring of the trial section shall
include all items listed in the South African Pavement Engineering Manual (SAPEM) Chapter 12, Table 11 and Chapter 12: Appendix – Asphalt
Trial Section Check List.
The Contractor shall calibrate the equipment and refine the mix design and construction process at his own cost.
The Engineer may require that up to 3 different binder contents be incorporated in one such trial section to verify the laboratory, and or, plant
design phase and its behavior/properties at the specified layer thickness being constructed.
The Contractor shall only commence with construction of the permanent work when such a trial section has been satisfactorily constructed and
complies with all the specified requirements.
work.

Asphalt may be mixed and placed only under favorable weather conditions and shall not be mixed or placed when rain is imminent or during misty
or wet conditions. The following wind and temperature conditions shall be applicable:
• 6°C and temperatures are rising with an allowable wind velocity of less than 25 km/h
• 10 °C with an allowable wind velocity of less than 55 km/h for layers paved > 30 mm thick
• 10 °C with an allowable wind velocity of less than 25 km/h for layers ≤ 30 mm thick
With falling air temperature, paving shall cease when the air temperature reaches 6 °C regardless of the wind velocity, and may not be restarted
before the temperature is definitely rising.
Where specifically ordered by the Engineer for emergency safety or traffic accommodation reasons, paving operations shall comply with the
recommendations listed in: Sabita Manual 22: Hot Mix Paving in Adverse Weather.
The mixing and placing of asphalt shall not be permitted under the following conditions:
• The moisture content of the aggregate affects the uniformity of mix temperature
• Free water is present on the working surface, or if
• The moisture content of the upper 50 mm of a granular base layer exceeds 50 % of the optimum moisture content, as determined by the
Engineer.
Immediately after a rainy spell on an existing partly cracked and/or highly permeable surfacing and/or primed base resulting in the trapping of
moisture in the pavement structure. In such case the base shall be allowed to dry out to meet the above moisture content requirements prior to
placing the asphalt layer.
A9.1.3.5 Surface requirements

Immediately before applying the specified bond coat the surface shall be broomed and cleaned of all loose or deleterious material before
commencing with any paving. Where the prime coat (if any) has been damaged, it shall be repaired by hand brushing or spraying priming material
over the damaged portions, which shall be allowed to cure prior to commencing paving. Where the surfacing is to be constructed on bridge decks,
the concrete deck shall be thoroughly cleaned by washing and brushing to remove all loose material and curing compound and then allowed to
dry prior to application of the specified bond coat.
The base or the subbase, as the case may be, (after the prime coat has been applied), shall be checked for smoothness and accuracy of grade,
elevation, cross section as well as any visible damage. Any portion of the base or subbase layer not complying with the specified requirements
shall be corrected with asphalt at the Contractor’s own expense, until the specified requirements are met. The Engineer may however, in his sole
discretion, allow minor surface irregularities to remain, provided that the final asphalt layer conforms to the requirements of the specification.
The asphalt used for the correction of the base or subbase, shall be the same mixture as specified for the surfacing, or as directed by the Engineer.
The maximum size of aggregate used in the mix shall be dictated by the maximum required thickness of the correction layer in each case.
Notwithstanding these provisions, the Engineer reserves the right to order the removal and reconstruction of the layer, or of portions of the layer
not complying with the specified requirements instead of allowing the correction of substandard work with asphalt material.
The prime coat shall be dry before further bond coats or layers are applied. No work shall commence with the application of the bond coat and/or
the paving without the approval of the Engineer.
A9.1.4 DESIGN BY THE CONTRACTOR

A9.1.4.1 Mix designs
The fundamental mix type, stone or sand skeletal, as well as the associated sub-group and design level requirements, shall be as specified in the
Contract Documentation. The asphalt design shall be reported on the latest version of the D3 Design form (Asphalt Mix Design) as listed in
Appendix A of the South African Pavement Engineering Manual (SAPEM) published by the South African National Roads Agency SOC Ltd
(SANRAL). Updated version of the D3 Design Form should be used. No asphalt layers shall be constructed unless the specified, or other

appropriate and accepted, mix design process has been carried out by the Contractor and submitted to the Engineer on the above form for
assessment and approval.
A9.1.4.2 Mix design requirements

Unless otherwise specifically approved, the mix design methodology to be followed, appropriate mix volumetric properties, as well as all other
relevant performance property criteria, shall conform to the relevant listed requirements as contained in the latest published version, at the time
of tender, of the appropriate Sabita Manuals, for the following specific mix types as listed.
• Stone skeletal mixes:
- Continuous graded mixes: The latest version of Sabita Manual 35; Design and Use of Asphalt in Road Pavements. The design
processes may consist of up to four levels as appropriate for the mix type as specified and relevant to the expected performance
demands/risks. The level of design required shall be as stated in the Contract Documentation. The final mix proportions and properties
shall conform to the requirements as tabled in Sabita Manual 35 for the specific mix type and design level prescribed.
- Stone mastic asphalt (SMA) mixes: The latest version of Sabita Manual 35, Appendix B
- High Modulus Asphalt (EME) mixes: The latest version of Sabita Manual 33: Design Procedure for High Modulus Asphalt (EME) for the
specific class prescribed.
- Gap and continuously graded asphalt mixes incorporating bitumen-rubber: The latest version of Sabita Manual 19: Guidelines for the
Design, Manufacture and Construction of Bitumen-Rubber Asphalt Surfacings.
- Porous asphalt mixes: The latest version of Sabita Manual 17: Design of Porous Asphalt Mixes.
• Sand skeletal mixes
- Continuous, semi-gap and gap graded mixes: The latest version of Sabita Manual 35
- Continuous and gap graded mixes incorporating bitumen-rubber: The latest version of Sabita Manual 19: Guidelines for the Design,
Manufacture and Construction of Bitumen-Rubber Asphalt Surfacings.
• Any other specific mix types shall be designed in accordance with the Contract Documentation requirements.
• Independently certified as being fit for the intended purpose, such as Agrément SA, or any other independent certification authority as
approved by the Engineer.
In all instances the mix properties shall conform to the latest requirements as listed in the relevant publications above for the mix type, class and
design level specified.
The following shall, in all instances, be indicated in the Contract Documentation:
- Mix type (stone or sand skeletal mix)
- Specific mix type within the above categories
- Level of design required, as appropriate for the specific mix type specified
- Nominal maximum particle size (NMPS) of the aggregate
- Binder type
- Nominal layer thickness
Where the incorporation of warm mix asphalt technology has been prescribed in the Contract Documentation, provision has been made in Part
C: Measurement and Payment, for any extra over/under rate as may be applicable. WMA technology may be used provided that the performance
criteria of HMA is met and the only change is the mixing and placement temperature ranges.
Asphalt designed and constructed under performance based systems with, or without, extended guarantee periods shall be treated as prescribed
in Part D of these specifications, or as otherwise stated in the Contract Documentation.
Before any asphalt is placed on the road, the Engineer shall review and accept the mix design. In the case of performance based specifications,
the Engineer reserves the right to have any proposed asphalt mix design independently verified. The approval process shall be as follows:
- The Contractor shall prepare and submit a proposed laboratory design mix with test results at four different binder contents. The design
mix shall be submitted on the prescribed design form D3 with all relevant testing completed.
- Samples of all proposed components shall be submitted together with the laboratory design mix results to enable the Engineer to carry
out check design testing if required. The above design and its components shall be submitted to the Engineer at least two weeks before
it is intended to commence with any asphalt production.
- After initial approval is obtained for the laboratory design mix, a plant mix at varying binder contents, approximately 0,3 % above and
below the expected target binder content. The quantity of asphalt at each point shall not be less than 20 tons. The purpose of the plant
mix is for the Contractor to prove that the laboratory design mix can be produced successfully and meets all the specified mix properties.
The Engineer may conduct any necessary confirmation testing on the plant mixes. The plant mixes shall not be placed on the road.
During the production of the plant mix, the Engineer shall be afforded the opportunity to inspect the asphalt plant.
- After the plant mix is approved, permission shall be given for laying a trial section at varying binder contents in accordance with the
requirements of Clause A9.1.3.3 of these specifications. The Engineer may require that the mix be further assessed by any additional
test methods, the cost of which will be borne by the Employer. Mass production of asphalt shall only commence after approval of the
trial section, which shall be given within a maximum of ten calendar days.
- Final grading and mix proportions will be approved by the Engineer after three days of full production.
A9.1.4.3 Changes to mix components

The Engineer shall instruct the Contractor at any time to halt his paving process and to review the whole, or part, of the above process should:
• the specified asphalt mix properties not be met
• a consistent asphalt mix is not being produced.
• a change of any aggregate properties is identified
A9.1.4.4 Mix design period

As different design methodologies or levels have minimum time periods for completion, assessment and approval, the Contractor shall ensure
that he commences the specified design processes for the specific mix type and design level timeously to ensure that there are no delays to his
construction program. The minimum time that shall be allowed for in the construction program is:
Sabita Manual 35: Level 1: 6 weeks

Sabita Manual 17 (Porous asphalt): 8 weeks
Sabita Manual 19 (Bitumen-rubber mixes): 8 weeks
Sabita Manual 33 (EME): 12 weeks
The Engineer may permit the commencement of construction of asphalt layers prior to the full asphalt mix design protocols, as specified, being
submitted for formal acceptance. In such instances the Contractor shall prove that historical mix design data obtained by an accredited testing
laboratory meets all the specified mix design properties, and that the relative properties of the current individual mix constituents to be incorporated
are essentially similar to those utilised at the time of the original design. Any such concession shall, however, not absolve the Contractor of any
obligations with respect to submitting a current valid mix design for evaluation and acceptance, and constructing asphalt layers that conform in all
respects to the specified requirements.
A9.1.4.5 Cost of designs

Provision has been made under Measurement and Payment for the costs associated with producing, for each mix, and or, binder type specified,
a single laboratory mix design followed by plant mix verification confirming conformance to the particular design method and product properties
specified. Any changes to individual components, or properties of a mix, even after initial acceptance has been given, shall require that a new mix
design process be undertaken, with any extension of time and cost implications for re-design and trial section at the cost of the Contractor.
If, however the Engineer issues an instruction to change any component, or mix type, for whatever reason, the Contractor shall, in such instances
be entitled to claim the cost for additional designs and time at the relevant rates tendered and as approved by the Engineer.
A9.1.5 MATERIALS
A9.1.5.1 General
The Contractor shall, as often as necessary, and in accordance with his approved quality plan, test and control the materials produced by himself,
or any materials received by him from suppliers, to ensure that the materials are uniform and always comply with the specified requirements.
Refer to the latest version of Sabita Manual 5: Guidelines for the manufacture and construction of hot mix asphalt.
Sufficient aggregate and bituminous binder for a minimum of 3 days production shall be separately stockpiled/stored and tested for conformance
and uniformity prior to use. The test results shall be made available to the Engineer on request.
A9.1.5.2 Bituminous binders for asphalt mixes

The binder type to be used in a specified mix shall be as prescribed in the Contract Documentation. The specific properties relating to each binder
type/class are not specified here but shall conform to the relevant requirements/ product properties as listed in the latest version of the appropriate
publications below, or as may be specifically stated in the Contract Documentation.
- Penetration grade: Conventional bitumen of standard grades and properties as specified in SANS 4001-BT1
- Performance grade: As specified in SATS 3208 – which covers standard bitumen or modified bitumen
- Homogenous modified binders: Penetration grade bitumen modified with appropriate polymers to achieve the specific class and relevant
properties as listed in the latest version of Technical Guideline (TG1) - (Modified Binders for Road Construction) as published by the SABITA
or Performance Grade as specified in the Contract Documentation.
- Non-homogeneous modified binders (bitumen-rubber): A blend of penetration grade bitumen, rubber crumbs and any extender oils to achieve
the specific class/grade and relevant properties as listed in the latest version of TG1 (Modified Binders for Road Construction –as published
by SABITA) or Performance Grade as specified in the Contract Documentation.
- Bitumen emulsion: A mixture of normal penetration grade bitumen which has been suitably emulsified with water to achieve the specific
class/grade as specified. The relevant requirements and properties pertaining to a specific class/grade shall be as listed in SANS BT4001-
BT4 to BT6.
- Modified bitumen emulsion: A mixture of conventional bitumen and appropriate polymer that has been suitably emulsified with water to
achieve the specific class/grade and properties as listed in the latest version of Technical Guideline TG1 (Modified Binders for Road
Construction) as published by the SABITA
Notwithstanding initial conformance of any modified bituminous binder property as may be specified, such products shall be blended, transported,
stored and utilized in accordance with all the accepted best practice guidelines/requirements as published in the latest versions of the SA Asphalt
Academy and/or, South African Bitumen Association Guideline documents as relevant for that particular product.
If the Engineer suspects that bitumen or asphalt has been overheated, he may order that the bitumen, or the bitumen recovered from the asphalt,
be subjected to the n-Heptane-Xylene (Spot Test) as described in AASHTO-T102. Recovery of the binder from the mixed asphalt for use in the
Spot Test shall be carried out in accordance with SANS 3001-AS25. Any bitumen having an n-Heptane-Xylene equivalent in excess of 36, or in
excess of the manufacturers test result on the dispatched stock, shall be considered to have been overheated and shall be rejected unless proven
otherwise.
A9.1.5.3 Bitumen bond coat

Unless otherwise specified in the Contract Documentation, the bond coat shall consist of a stable grade bituminous emulsion diluted to have a 30
% net bitumen content. The use of polymer modified emulsions, or any other product as may be certified as fit for the specific purpose, shall be
as specified in Part D of these specifications or in the Contract Documentation.
A9.1.5.4 Aggregates
a) Aggregate properties
Aggregate shall consist of hard material derived from the crushing of solid rock or boulders. Coarse and fine aggregate shall be clean and free
from decomposed materials, vegetable matter or any other deleterious substances, and shall meet the requirements listed in Table A9.1.5-1 below
unless otherwise specifically stated in the Contract Documentation. All aggregates shall be handled and stockpiled in a manner that will prevent
contamination, segregation or degradation.
Asphalt mixes shall be manufactured using individual single size coarse aggregates fractions and crushed fine aggregates complying with the
latest version of SANS 1083 and appropriately blended to conform to the target grading as determined by the selected design methodology. The
use of natural sands shall only be permitted if approved by the Engineer and shall be limited to a maximum of 7 % by mass for continuously
graded mixes. For stone mastic asphalt mixes all aggregate fractions in excess of 2,0 mm shall consist of individual nominal single size fractions.

Once the target grading has been fixed for each individual fraction, the allowable tolerances shall not exceed that specified in SANS 1083. The
Contractor shall note that commercial suppliers may not be able to consistently supply all the required single size aggregate, in which instance
additional on-site screening may be required, for which no additional payment shall be made. The use of run of crusher type materials shall not
be permitted.
Table A9.1.5-1: Aggregate properties
Property Test Standard Product Criteria
Sand skeletal mixes ≥ 160

Fines aggregate
SANS 3001-AG10
crushing test: 10% FACT (kN) ≥ 210
Stone skeletal mixes
Hardness / Sand skeletal mixes ≤ 25
Toughness
Aggregate crushing
SANS 3001-AG10 Stone skeletal mixes ≤ 21
value (ACV)
Rolled in chippings: ≤ 21
Magnesium sulphate soundness SANS 5839 12 - 20
Soundness All
(%) SANS 3001-AG12
≤5
Methylene blue adsorption
Durability SANS 6243 All > 5: additional testing and
indicator
analysis needed
20 mm and 14 mm aggregate ≤ 25*1
10 mm and 7,1 mm aggregate
Rolled in chippings ≤ 30
Flakiness index SANS 3001- AG4
≤ 20
Polished stone value (PSV) SANS 3001–AG11 Coarse aggregate for surfacing ≥ 50*2
Particle shape and Sand skeletal mixes At least 50 % of all particles
texture should have three fractured
faces
Fractured faces ASTM 5821 Stone skeletal mixes and At least 95 % of all particles
rolled in chippings should have 3 fractured faces
SANS 3001-AG20 Coarse aggregate (>5,0 mm) ≤ 1,0

Water absorption % by mass
SANS 3001- AG21 Fine aggregate (< 5,0 mm) ≤ 1,5
Binder absorption % by mass SANS 3001 – AS11 Coarse and fine aggregate ≤ 0,5
Sand equivalency test SANS 3001-AG5 Total fines fraction ≥ 50
Cleanliness Clay lumps and friable Particles ≤ 1,0
ASTM C142–97 Coarse and fine aggregate
(%)
1
For certain types of mixes, e.g. UTFC, a maximum flakiness index of 20 may be required
2
If approved by the Engineer, a limiting value of 45 may be accepted with due regard to material availability, traffic, road geometry and expected
climatic conditions.
b) Coarse aggregate grading
(i) The coarse aggregate component of any asphalt mix shall comprise of nominal single aggregate sizes conforming to the specific
aggregate grading class and appropriately blended in the mixing plant. The blend shall be relevant to the mix type and layer
thickness specified. The nominal maximum particle size (NMPS) utilised in any mix shall not exceed the maximum limits listed in
Table A9.5.1-2 below.
Table A9.1.5-2 NMPS versus nominal layer thickness requirements
Minimum layer thickness (mm))
NMPS [mm]
Absolute minimum Preferred minimum
7,1 20 25
10 30 35
14 45 50
20 80 90
28 110 120
(ii) Coarse aggregate grading class

Unless otherwise specifically permitted, the coarse aggregate components of any asphalt mix shall comply with the grading limits
tabled in Table A9.1.5.-3 below for the relevant grading class and NMPS as listed. The grading class applicable to the relevant mix
type shall be as follows:

Grading class 1:
- Continuously graded: stone skeletal
- High modulus asphalt (EME)
- Gap graded: stone skeletal mixes
- Ultra-thin friction courses (UTFC)
- Stone mastic asphalt (SMA)
- Porous asphalt
Grading class 2:
- Continuously graded: sand skeletal
- Semi-gap: sand skeletal mixes
- Gap graded: sand skeletal mixes
Table A9.1.5-3: Grading limits for nominal single size coarse aggregate
Nominal maximum particle size (NMPS) (mm)
28,0 20,0 14,0 10,0 7,1 5,0
Grading 1 2 1 2 1 2 1 2 1 2 1 2
grade
Sieve Percentage passing sieve size by mass
size
(mm)
37,5 100 100 - - - - - - - - - -
28,0 85-100 85-100 100 100 - - - - - - - -
20,0 0-20 0-35 85-100 85-100 100 100 - - - - - -
14,0 0-5 0-5 0-20 0-35 85-100 85-100 100 100
10,0 0-5 0-5 0-20 0-35 85-100 85-100 100 100
7,1 0-5 0-5 0-20 0-35 85-100 85-100 100 100
5,0 0-5 0-5 0-20 0-35 85-100 85-100
Once the target grading has been fixed for each individual coarse aggregate fraction, the allowable tolerances shall not exceed 10 % of that
agreed for the target grading for each specific nominal maximum aggregate particle size. The Contractor shall note that commercial suppliers may
not be able to consistently supply all the required nominal single size aggregate to the specified tolerances. In such instances additional on-site
screening may be necessary, for which no additional payment shall be made. The use of run of crusher type materials shall not be permitted.
c) Fine aggregate grading
If approved by the Engineer, and if the specified mix properties are met, the fine aggregate component may contain natural fines not obtained
from the parent rock being crushed, on condition that such added material does not exceed 7,0 % by mass, unless otherwise specified in the
Contract Documentation. The added fines shall have a liquid limit not exceeding 25 % and a PI not exceeding 4. The Contractor shall submit full
details regarding the exact quantity and nature of such fine aggregate, before such permission will be considered. In the event of such added
material being natural sand, its impact on final mix properties shall be assessed from laboratory briquettes and cores obtained in the trial section.
The addition of natural fines shall only be by means of a separate plant cold-feed bin.
Table A9.1.5-4: Fine aggregate grading limits for relevant mix type
Grading Grade 1 Grade 2 Stockpile
Grade Tolerance
Percentage passing by mass
Sieve Size Class 1 Class 2
(mm) Percent Passing Percent Passing
Stone skeletal mixes as defined Sand skeletal mixes as defined

7,1 100 85 - 100 5%
5 90 - 100 70 - 90 5%
2 65 - 90 45 - 70 5%
1 45 - 70 28 - 50 5%
0,6 30 - 50 19 - 34 5%
0,3 18 - 30 12 - 25 4%
0,15 10 - 21 7 - 18 3%
0,075 5 - 15 5 - 15 2%
When determined in accordance with SANS 3001-AG1, the Fineness Modulus (FM) of both the crushed and natural fine aggregates shall not
deviate by greater than 0,2 from that determined on the fine aggregate incorporated in the approved design mix.

d) Combined aggregate grading
The combined grading selected shall be relevant to the mix type and design level as specified and shall be determined by means of the specified
mix design methodology prescribed in Clause A9.1.4.2 and shall be appropriately optimised to ensure conformance to all the specified mix
properties as relevant.
Continuously graded sand skeletal asphalt mixes shall be designed in accordance with the method listed in Sabita Manual 35: Design of Hot Mix
Asphalt, and the grading shall fall within the control points listed in Table A9.1.5-5 for the specified nominal maximum particle size (NMPS) of
aggregate as prescribed. Notwithstanding these control point limits, during the design process, the grading of the mix shall be optimised utilising
appropriate means, such as the “Bailey” Method as outlined in Appendix A of Sabita Manual 35 to ensure that the specified volumetric and
performance properties of the final mix, as specified, are optimised in all respects.
Table A9.1.5-5: Aggregate grading control points for a continuously graded sand skeletal mix (Sabita Manual 35)
Nominal Maximum Particle Size (NMPS)
Sieve size (mm)
28.0 20.0 14.0 10.0
37,5 100
28 80 - 100 100
20 < 85 80 - 100 100
% passing sieve size by mass
14 < 85 80 - 100 100

10 < 85 80 - 100
7,1 < 85
5
2 19 - 45 23 - 40 28 - 58 32 - 67
1
0,600
0,300
0,150
0,075 4,0 – 7,0 4,0 – 8,0 4- 10 4 - 10
The grading control points shown in Table A9.1.5-5 shall be considered as a guideline only and not a specification grading envelope.
Where the use of reclaimed asphalt has been prescribed, the reclaimed asphalt shall be crushed, screened, stockpiled, protected, tested and
utilised in accordance with the requirements contained in the latest version of Sabita Manual 36: Use of Reclaimed Asphalt in the Production of
Asphalt.
For open and gap graded mixes the proposed grading for the combined aggregate in the mix shall be as specified in the Contract Documentation
or if not specified, then the guidelines in Manual 35 and the applicable Sabita Manuals shall apply, e.g. Manual 17 for open graded mixes, Manual
19 for bitumen rubber mixes and Manual 33 for EME. Stone skeletal mixes and SMA shall follow the guidelines in Manual 35.
The grading of the combined aggregate, including any filler added, in an accepted mix design shall be designated as the target grading. Allowable
tolerances from such an approved target grading during production shall be as specified in Clause A9.1.8.5.
e) Rolled in chippings grading
The grading requirements for rolled in chippings shall be as listed in Table A9.1.5-6.
Table A9.1.5-6: Grading limits for rolled-in chippings
Percentage passing sieve size by mass by
mass
Sieve size (mm)
20,0 mm 14,0 mm 10,0 mm
-
20,0 100 -
14,0 0 – 20 100
100
10,0 0–5 0 – 20
7,1 0–1 0–5 0 – 20
0,425 0,5 max 0,5 max 0,5 max
A9.1.5.5 Fillers
Should the grading of the combined aggregates for asphalt mixes show a deficiency in fines, an approved filler may be used to improve the
grading. With the exception of stone mastic asphalt, in no instance shall more than 2 % by mass of active filler be used in a mix. Inert filler such
as rock dust used to improve a grading shall not be subject to this limitation. No payment will be made for any filler added to improve the grading.
The Engineer may order the use of any active filler to improve the adhesion properties of the aggregate. Active filler shall consist of hydrated

lime, ordinary Portland cement, Portland blast furnace cement, fly-ash or a mixture of any of the above materials. Individual materials shall comply
with the requirements of the relevant SANS or other specifications for such material. Active fillers shall be used in the order in which they have
been received.
A nominal active filler content of 1 % by mass is included for tender purposes and shall be included in the mix unless otherwise specified. For
tender purposes the active filler shall be hydrated lime or as per the Contract Documentation. If no active filler is added, the cost of the nominal 1
% filler shall be deducted from the unit rate, at the variation rate tendered. The Contract Documentation must consider the use of adhesion
promoters and alternative active fillers and as such should be measured separately in the schedule of quantities. The actual active filler and
adhesion promoters will be determined by the mix design and paid for under the variation items.
Table A9.1.5-7: Filler requirements
Limit
Type of filler/origin Property Test method
70 minimum
Active filler: Grading: % passing 0,075 mm 0,5 – 0,9 g/ml
Hydrated lime Bulk density in toluene 0,3 – 0,5 % SANS 3001-AG1
Portland cement Voids in compacted filler 5 maximum BS 812
Methylene blue test BS 812
SANS 6243
Non- Active filler: As above

As above for active fillers
Fly ash
Baghouse fines Refer Contract Documentation
Limestone dust Refer Contract Documentation
A9.1.5.6 Fibres
A nominal cellulose fibre content has been allowed for in stone mastic mixes. The Contractor shall prove that the fibre he intends using has the
proven ability to prevent any drain down of the bitumen in the mix during transportation and placing without compromising the in-place mix
properties.
A9.1.5.7 Bitumen rejuvenators

Where the use the use of reclaimed asphalt is permitted or prescribed, the percentage, and existing binder properties, of such material incorporated
into the final mix as well as the limits of binder replacement shall dictate whether a bitumen rejuvenating agent is required to be added, or not. No
specific product, or quantity thereof, is prescribed. The Contractor shall however follow the generally accepted good practice guidelines contained
in latest version of Sabita Manual 36: Use of Reclaimed Asphalt in the Production of Asphalt. The Contractor shall provide the Engineer with
sufficient proof that the product intended for use has a proven capability of producing a final bitumen product meeting all the requirement of the
binder type specified, and that the final asphalt mix meets all the relevant properties as specified. No additional payment shall be made for including
these products, the cost of which shall be deemed to be included in the relevant unit rates tendered for the specified constructed asphalt layers.
A9.1.5.8 Mix properties

The properties of the mix shall be relevant to the mix type and design level prescribed in the Contract Documentation. In all instances the specific
mix properties shall conform to the latest requirements, as relevant for the mix type and required Design Level, as published in the following
Manuals as listed below:
a) Stone skeletal mixes
- Continuously graded: Sabita Manual 35: Design and Use of Asphalt in Road Pavements.
- High modulus base (EME): Sabita Manual 33: Design of High Modulus Asphalt Bases (EME)
- Bitumen Rubber mixes: Sabita Manual 19: Design of Bitumen Rubber Wearing Courses
- SMA: Sabita Manual 35: Design and Use of Asphalt in Road Pavements – Appendix B
- Porous Asphalt: Sabita Manual 17: Design of Porous Asphalt Mixes
b) Sand skeletal mixes
- Continuously graded: Sabita Manual 35: Design and Use of Asphalt in Road Pavements.
- Semi-gap graded: Continuously graded: Sabita Manual 35: Design and Use of Asphalt in Road Pavements.
- Gap graded: Sabita Manual 35: Design and Use of Asphalt in Road Pavements.
- Residential applications: Sabita Manual 35: Design and Use of Asphalt in Road Pavements and Sabita Manual 27: Design of Asphalt Wearing
Courses on Residential Streets
A9.1.5.9 Asphalt reinforcing

Asphalt reinforcing shall be of the type specified in the Contract Documentation and shall be obtained from an approved manufacturer.
Where the use of reinforcing for asphalt has been specified, the Contractor shall, at least 3 months before the material is to be used, submit
samples of the type he intends to use, together with complete specifications of the material, as well as the manufacturer's instructions for use, to
the Engineer for approval. In general, the product shall be installed according with the best practice guidelines contained in the latest version of
Technical Guideline (TG) 3, as published by the SABITA. Where the material does not carry the SABS mark, or the mark of another acknowledged
authority, the Engineer may instruct the Contractor to have the material tested by an approved laboratory and to submit the results.

A9.1.6.1 General
Where asphalt for the project is sourced from a mobile asphalt plant, the Contractor must obtain assurance in writing that the establishment and
operation of such mobile asphalt plant is in accordance with the National Environmental Management Act: Air Quality Act 2004 (Act No 39 of

2004) and the National Environmental Management Act, 1998. These items to also be included in the regular site audit protocol to ensure ongoing
compliance.
All plant shall be so designed and operated as to produce a mixture complying with the requirements of this specification. The plant and equipment
used shall be of adequate rated capacity and be in good working order. Obsolete or worn-out plant shall not be permitted on site. Mobile plant
with hydraulic or petroleum product oil leaks shall be immediately repaired or removed from site.
Prior to the start of the work the Contractor shall supply the Engineer, on request, with copies of the manufacturer's handbooks and copies of
check lists prepared in terms of ISO 9002, where applicable, pertaining to the mixing and paving plants, containing details of the correct settings
and adjustments of the plant.
Any alteration which has been, or is being effected to any constructional plant, and which does not comply with the specifications of the
manufacturer, shall be brought to the notice of the Engineer.
A9.1.6.2 Mixing plant

Asphalt shall be mixed by means of an approved mixing plant of proven suitability for producing a mixture complying with all the requirements of
the specifications.
The heating system of the binder storage tanks shall be so designed that the binder will not be degraded during storing, heating and production.
A circulating system for the binder shall be provided which shall be of adequate size to ensure the proper and continuous circulation between
storage tanks and mixer during the entire operating period.
Binder storage tanks shall be fitted with thermometers designed to provide a continuous record of the temperature of the binder in the tank. Copies
of these records shall be supplied to the Engineer on a daily basis.
The binder content of the mix shall be controlled within the tolerances specified, either by weighing or by volumetric measurements. The system
shall be controlled by the cold feeding of each aggregate fraction, and filler, by mass, by means of a load cell or other devices regulating the feed
automatically. Suitable dust collecting equipment shall be fitted to prevent pollution of the atmosphere in accordance with the provisions of the
latest laws and relevant regulations.
Where more than 10 % (drum mixers) or 15 % (batch mixes) of reclaimed asphalt is to be utilised in the mix, the mixing plant shall be of such a
design and configuration as to produce a recycled mix containing the prescribed, or selected, percentage of reclaimed asphalt without any
premature ageing of the mix occurring. In general, the requirements for appropriate mixing plants to be used for recycling shall be as recommended
in the latest version of Sabita Manual 36: Use of Reclaimed Asphalt in the Production of Asphalt.
A9.1.6.3 Paver
The mixture shall be laid by an approved type of self-propelled mechanical spreader and finisher fitted with automatic electronic screeds, capable
of paving to the required widths, thickness, profile, camber or cross-fall without causing segregation, dragging, tearing, or other surface defects.
Where leveling beams on multiple skids or sliding beams are used they shall be at least 12,0 m long, or as specified in the Contract Documentation.
A9.1.6.4 Chip spreader

The chip spreader shall straddle the full width being paved and shall be used for spreading the rolled in chippings. Such a mechanical spreader
shall be self-propelled and be able to follow immediately behind the paver.
When coated chippings are spread by hand in restricted areas, special care shall be taken to prevent bunching of the chippings.
A9.1.6.5 Rollers
Compaction shall be done by means of approved flat steel-wheeled, vibratory or pneumatic-tyre rollers. The frequency as well as the amplitude
of vibratory rollers shall be adjustable. Vibratory rollers shall be used only where there is no danger of damage being done to the asphalt, and to
the smoothness of the layer, bridge decks, or other layers. It will be indicated in the Contract Documentation whether any vibratory compaction
equipment may be used on bridge decks, and what the constraining parameters will be. The rollers shall be self-propelled and in good working
condition, free from back lash, and without any oil leaks. Rollers shall be equipped with adjustable scrapers to keep the drums clean and with
efficient, fully functioning means of keeping the wheels wet to prevent mixes from sticking to the rollers. Approved release agents may be used
on roller wheels but the use of petroleum products for this purpose shall not be permitted. The mass and tyre pressures shall be such so as to
ensure compaction complying with the specifications for surface finish and compaction.
The required type, and number, of rollers to be utilized shall be appropriate to the mix type being paved and rate of paving which shall be as
determined during the trial section. The Contractor shall take adequate precautions to eliminate any pick-up of the paved mat. For open-graded
asphalt and/or stone-mastic asphalt, only flat steel-wheeled rollers shall be used.
A9.1.6.6 Binder distributors

The bituminous binder bond coat shall be applied either by means of a “self-tacking” paver or by an approved binder distributor as follows:
Comply with SANS 3001-BT20 and shall be covered by a valid certificate of compliance with SANS 3001-BT20, not older than 12 months, issued
by an accredited testing organisation;
Not have any fuel, oil or binder leaks;
Have a straight and clean spray bar, all the spray heads of which shall be of the same type which open simultaneously and shall not leak when
closed;
Have its spray heads all spraying at the same angle to the spray bar and the height adjusted to the correct level so as to obtain the required
overlapping. The uneven application of binder shall be unacceptable;
Have its sieve undamaged and clean;
Be under the direct control of an operator approved by the Engineer on the grounds of a reference, in writing or a certificate of competence signed
by a representative of a road authority;
Be fitted with a suitable cut-off spray-head (end nozzles) or fishplates to prevent over spraying onto gravel shoulders or staining of concrete
elements on the edge of the surfacing of the road.
Be capable of spraying the binder at the specified applications rates and to the satisfaction of the Engineer. The pump of the distributor shall be

capable of delivering the binder at the spray bar nozzles at the correct pressure to obtain the specified application rates, irrespective of the viscosity
properties of the prescribed binder and the number of nozzles open.
Fitted with a suitable valve or other access gate for taking of samples of the binder for testing purposes.
Hand sprayers, other than in restricted areas, shall only be permitted if so approved by the Engineer.
A9.1.6.7 Vehicles
The asphalt shall be transported from the mixing plant to the spreader in tip trucks that are in good condition having no oil leaks. They shall have
tight, clean smooth beds and sides that have been treated to prevent adhesion of the mixture to the truck bodies. A thin film of soapy water,
vegetable oil or approved release agents may be used to prevent adhesion but petroleum products shall not be used for this purpose. The truck
bins shall be designed to tip asphalt into the paver’s hopper without spillage.
To minimize temperature loss, all vehicles used for transporting asphalt to the site shall be fitted with appropriate bin covers. Where the expected
transport, and or, storage time of the asphalt is expected to exceed one hour in the truck, the use of thermal asphalt covers (canvas covers not
acceptable) shall be obligatory.
A9.1.6.8 Material transfer vehicle

Where so specified, and provision thereof is included under Measurement and Payment, asphalt shall be transferred from the haul trucks into the
paver hopper by means of a materials storage and transfer vehicle and no material shall be tipped directly from the truck into the paver with the
exception of paving in restricted areas.
The materials storage and transfer vehicle shall be capable of storing and transferring the asphalt from truck to paver to ensure continuous paving.
It shall contain an anti-segregation auger that remixes the asphalt just prior to delivery to the paver hopper in order to ensure a mix of uniform
temperature.
A9.1.6.9 Mass-measuring device for asphalt mixes

Where payment per ton is specified, the Contractor shall keep available, at the mixing plant or on the site, a suitable calibrated mass-measuring
device for measuring the mass of asphalt being delivered. The device shall be provided with a means of electronically recording and printing the
type of mix, the mass, the time and the date. The printed data shall be submitted to the Engineer.
A9.1.6.10 Milling machine

Where so required and scheduled, the Contractor shall provide a suitably sized milling machine to mill off existing asphalt on bridge decks and or
to mill an appropriate keyway at the approaches to bridge structures. The size of the milling machine shall be such as to allow milling adjacent to
bridge nosings and any joints without damaging them.

A9.1.7.1 Production of the mixture
a) Mixing and storage temperatures
Penetration grade and modified bitumen shall be stored at temperatures not exceeding those given in the SANS specifications and TG1: Modified
bitumen for Road Construction as relevant for the particular bitumen incorporated. The aggregate and bituminous binders shall be heated in the
mixing plant to such temperatures that the mixed product shall have a temperature within the range given in Table A9.1.7-1.
Table A9.1.7-1: Temperature ranges for storage & mixing
Maximum storage
Mixing Temperature range of mix °C
temp of binder °C
Product Continuously,
Over 24 Under 24
semi-gap and gap Open graded mixes
hrs. hrs.
graded mixes
35/50 penetration grade 145 175 140 – 165 110 - 140
50/70 penetration grade 135 175 135 – 160 105 – 135
80/100 penetration grade 125 175 130 – 155 100 – 130
150/200 penetration grade 115 165 125 – 150 -
Non-homogeneous modified
Refer TG1 160 – 180 160 - 180
binders: Bitumen-rubber
Homogeneous modified binders Refer TG1
b) Mixing utilising batch plants

The aggregate shall be dried and heated so that, when delivered to the mixer, its temperature shall be between 0°C and 20°C lower than the
maximum temperature indicated in Table A9.1.7-1 for the mixture. The moisture content of the mix shall not exceed 0,5 %.
Each fraction of the aggregate and binder shall be measured separately and accurately in the proportions by mass in which they are to be mixed.
If filler is used, it shall be measured separately on a scale of suitable capacity and sensitivity. The error in the weighing apparatus used shall not
exceed 2 % for each batch.
The aggregate, filler and binder shall be mixed until a homogeneous mixture is obtained in which all particles are uniformly coated. Long mixing
times that cause age-hardening of the binder shall be avoided.

c) Mixing utilising drum plants
The aggregate and filler shall be accurately proportioned and conveyed into the drum-mixing unit. The calibrated amount of binder shall be added
to the aggregates at the correct position so that no hardening of the binder shall take place. A homogeneous mixture and uniform coating of
binder shall be achieved and the moisture content of the asphalt mixture shall not exceed 0,5 % when tested in accordance with SANS 3001-
AS23. Once the final mix temperature has been agreed upon it may not be altered without the prior consent of the Engineer.
Pre-blending of aggregate fractions shall not be permitted and the Contractor shall ensure that sufficient cold-feed bins are installed to
accommodate each individual aggregate fraction, including the filler.
d) Producing small quantities of asphalt
A small quantity of asphalt shall be a quantity of less than 10 tons of a specified composition to be specially produced on occasion. For a small
quantity of asphalt of less than 10 tons extra payment will be made if its use has been instructed by the Engineer, in writing and where, in the
opinion of the Engineer it is necessary, and shall be:
- In accordance with the approved working programme of the Contractor, and/or
- For the safety of the work or the travelling public on account of weather conditions or abnormal traffic conditions.
No extra payment will be made where small quantities of asphalt are required in consequence of the negligence of the Contractor or of poor
workmanship, or bad planning, done by the Contractor, or because he did not execute the works in accordance with his approved programme.
A9.1.7.2 Producing pre-coated chippings

Aggregate for pre-coated chippings shall be coated using the nominal percentage bitumen as listed in Table A9.1.3-8 ± 0,3 % by mass for the
relevant nominal maximum size specified. Unless otherwise approved, the grade of bitumen used to coat the chippings shall be 50/70 penetration-
grade. One per cent by mass of active filler, lime, shall be added to the mixture.
The aggregate shall be dried and fed into the approved batching plant at a temperature of between 130°C and 185°C followed by the bitumen at
a temperature not exceeding 175°C and filler. Immediately after the aggregate has been coated and discharged from the mixer it shall be allowed
to cool to below 90°C before dowsing with water.
Coated chippings shall be stockpiled in heaps not exceeding 1,0 m in height and protected if necessary to prevent temperatures from exceeding
60°C during storage.
A9.1.7.3 Storing the asphalt mix

Mixing shall not be allowed to take place more than four hours before paving begins unless provision has been made for storage in approved silos
which are capable of maintaining the temperature of the mix uniform throughout. Storage will not be permitted for a period longer than 8 hours
after mixing, unless otherwise approved by the Engineer. Open-graded mixes and stone-mastic asphalt shall not be stored or mixed ahead of
paving operations but shall be laid directly following mixing.
A9.1.7.4 Transporting of asphalt

The mixture shall be transported from the mixing plant to the works in trucks complying with the requirements of Clause A9.1.6.7. Deliveries shall
be made so that paving and rolling of all the mixtures prepared for a day’s production, can be completed during daylight hours, unless artificial
lighting, as approved by the Engineer, is provided. Any asphalt that has become cold or wet due to rain, or any other cause, shall be rejected.
Hauling over asphalt that has not cooled to ambient temperature shall not be permitted.
A9.1.7.5 Bond coat

In all instances, unless otherwise, specified, a bond coat shall be applied to the surface to be paved. Concrete curbing and channeling, as well as
any other adjacent structure or completed pavement shall be protected against staining by bitumen being sprayed or asphalt being placed. Where
any bitumen is to be sprayed, all such work shall be completely covered with polyethylene sheeting at least 0,25 mm thick, specially reinforced
paper, or other approved material adequately secured to prevent the sheeting from lifting during windy conditions. Any permanent work stained
by bitumen shall be broken down and replaced, unless all such bitumen is completely removed so as not to show any stains. Painting over stained
work is strictly prohibited.
Unless otherwise specified in the Contract Documentation, the bond coat shall consist of a stable-grade bituminous emulsion, diluted to have a
30 % net bitumen content, and shall be applied at a nominal rate of 0,55 (l/m²), or as directed by the Engineer. For bridge decks the bond coat
shall be applied to the surface at a nominal rate of 0,4 (l/m²). The bond coat shall not be applied more than 24 hours before the paving is to
commence and shall be fully cured prior to paving.
Before a new layer is placed adjacent to an existing layer, except in the case of open-graded or stone mastic mixes, the cut edge of the existing
layer shall be hand painted with a bond coat of bituminous material of the same type used for the substrate bond coat. The bond coat shall fully
coat the vertical face of the joint.
The use of hand-operated equipment for the application of bond coats, other than in restricted areas, shall be at the sole discretion of the Engineer,
and his approval shall be timeously obtained.
A9.1.7.6 Placing the asphalt

The mixture shall be delivered to the paver in such a manner that the paving will be as continuous as possible with minimal stopping. Any lengthy
delay in supply resulting in the asphalt mat cooling to below the appropriate compaction temperatures shall require that a construction joint be
formed prior to recommencing with the paving operation.
The temperature of the mixture shall be controlled by measuring in a random pattern in the truck immediately before emptying and shall not be
more than 10°C below the minimum mixing temperature, or above the maximum mixing temperature specified in Table A9.1.7-1. The adjustment
of the screed, tamping bars. Feed- screws, hopper feed, etc., shall be checked frequently to ensure uniform spreading of the mix. If segregation
or tearing occurs, the paving operations shall immediately be suspended until the cause is determined and corrected.
The addition or removal of material behind the paver shall not be allowed and the paver shall be capable of spreading the mixture to the levels
that will provide the specified compacted thickness
Only minimal hand-working of the gap graded asphalt shall be permitted after discharge from the paver and before rolling and shall only be carried
out with wooden spreaders. Workmen shall not be permitted to walk on un-compacted open graded asphalt.
Unless otherwise approved, paving shall commence at the bottom of the grades and the lower edges of super-elevated curves where the grades

are steeper than 5 %.
Paving widths shall be so planned that longitudinal joints do not coincide with joints in lower layers of asphalt base, paver laid crushed stone bases
or within the wheel paths of a lane.
Continuity of placing is especially important for open graded asphalt. Cutting of longitudinal joints shall be avoided when paving open-graded
asphalt but where cutting is essential, only saw cutting shall be permitted. The existing layer edge shall be heated by approved means in order
to ensure adequate longitudinal bonding of the asphalt between the two lanes.
Unless otherwise specified in the Contract Documentation the paver shall be equipped to provide automatic control of levels and cross section.
The mixer capacity and the operating speed of the paver shall be so coordinated so as to ensure continuous laying and thus avoid intermittent
stopping of the paver.
Paving shall cease when rain starts falling or when the surfaces to be paved are visibly wet.
In all cases, including leveling courses, the paver shall be provided with approved skid beams with electronically controlled equipment that can
ensure a constant cross-fall and can even out local irregularities.
Asphalt shall be placed in restricted areas with the aid of smaller specially equipped pavers, hand tools or other approved equipment. All the
requirements with respect to temperature, mix composition, uniformity, in-place properties etc. shall remain applicable but layer thickness and
control shall be such that the requirements for compaction and surface tolerances can still be achieved.
A9.1.7.7 Compaction
The compaction requirements for each mix type shall be in accordance with the requirements listed in the relevant Sabita Manuals as listed in
Clause A9.4.2 for the specific mix type prescribed. The sequence of rollers used in compaction shall be at the discretion of the Contractor provided
that the completed pavement shall meet the required compaction, profile, and surface texture as specified. The paved layer shall be compacted
as soon as possible after it has been laid by a combination of vibratory, static steel-wheeled and or pneumatic-tyre rollers in a sequence determined
and approved during the laying of trial sections. Rolling shall commence, and be continued, only for so long as it is effective and does not have
any detrimental effect.
Only steel-wheel rollers (non-vibratory) shall be permitted for the compaction of stone mastic asphalt as well as semi-open and open-graded
mixtures, although rubber tyre rollers may be on standby if required. During rolling the roller wheels shall be kept moist with only sufficient water
or an approved release agent to avoid picking up the material. The use of petroleum products or excesses of releasing agents (soap) to prevent
pick-up shall not be permitted. The use of vibratory rollers shall not be permitted on bridge decks.
Rolling shall commence from the edges of the paved mat and progress towards the center. On areas of super elevated curves, or where the
cross-fall exceeds 2 %, rolling shall commence on the low side and progress to the higher side, uniformly lapping each preceding track. During
breakdown-rolling the rollers shall move at a slow but uniform speed (not to exceed 5,0 km/h) with the drive roller nearest the paver, unless
otherwise specified on account of steep gradients.
Except for mixtures using warm mix asphalt technology, no movement of the asphalt layer shall occur under steel wheel rollers once the asphalt
temperature has dropped to below 100°C.
For thin layer asphalt (less than 30 mm) the compaction requirements shall be in accordance with the method statement as assessed and approved
in the accepted trial sections.
For open graded (Porous) asphalt the degree of compaction can be controlled indirectly by means of in-situ permeability tests calibrated during
the trial section and by visual evaluation of the aggregate to prevent crushing.
The Contractor shall utilize an appropriate and calibrated nuclear gauge for process control during compaction operations. Notwithstanding this
requirement, the acceptance control carried out to determine compaction shall still be based on cores taken from the compacted layer where the
layer thickness is appropriate.
A9.1.7.8 Applying rolled-in chippings

The size of pre-coated chippings used shall be as specified in the Contract Documentation. Unless specifically approved by the Engineer, the
chippings shall be laid by a mechanical spreader that straddles the paved width and follows immediately behind the paver. The chippings shall be
spread to give a uniform texture free from clusters and open patches. Unless otherwise specified in the Contract Documentation, the final surface
texture shall not be less than 0,8 mm and shall be demonstrated as being achievable in the trial section, as described in Clause A9.1.3.3.
Measurement of texture depth shall be in accordance SANS 3001-BT11, or by means of instrumentally measurements as described and specified
in Clause A20.1.5.5 of Chapter 20 “Tests on pavements”.
In restricted areas the Contractor may use hand tools for spreading chippings, in which instance the rate of application and requirements for
evenness of the spread chippings shall remain applicable.
A9.1.7.9 Cutting of joints

All joints between adjacent sections of the work shall be formed by cutting back the edges of the paved layer in a straight line, either parallel or at
right angles to the centerline, by a minimum of the width of the layer thickness being paved. Joints shall be neat and shall have the same texture
and compaction level as the adjacent asphalt layer.
All joints shall be delineated by means of chalk lines prior to cutting. For sand skeleton mixes, such as semi-gap and fine continuously graded
mixes, a cutting wheel may be utilized only if the layer is less than 50 mm in thickness and was paved within 24hours. For all other mix types,
layers in excess of 50mm, or that have been left for longer than 24hours, the joints shall be formed either by means of saw cutting, using
carborandum blades, or by an appropriate milling machine. All material emanating from preparing the joint shall be removed and transported to
an approved site for possible recycling or other appropriate use or disposal. No payment for any such removed asphalt shall be made.
On completion of preparing the joint, the adjacent surface shall be inspected to ascertain that there has been no damage caused to the adjacent
layer. Any identified damage shall be appropriately repaired prior to commencement of paving any adjacent asphalt layer.
Whenever the paving operation ceases due to lack of supply of mix, and the temperature of the mat has reduced to below the appropriate
compaction temperature, the Contractor shall form a proper transverse construction joint as specified.
Unless otherwise provided for, joints in the final layer of the surfacing shall correspond with the intended lane markings. Joints in lower layers
shall be offset by not less than 150 mm from either side of the edges of any underlying substrate joint.

The allowable tolerances for joints shall be as specified in Clause A9.1.8.3.
A9.1.7.10 Treatment of joints for traffic accommodation

Where it is necessary to accommodate public traffic during paving operations and the difference in level between the new work and the existing
road surface exceeds 25 mm, joints shall be treated as follows:
Transverse steps at the end of a day’s work shall be tapered off at a slope of 1 vertical to 20 horizontal (1:20) to tie in with the existing surface.
The tapered section shall be removed before surfacing is recommenced and a joint formed in accordance with Clause A9.1.7.7.
Longitudinal joints exposed to traffic shall be provided with a taper of compacted asphalt layer over the full length of the exposed joint. The width
of the taper shall be at least 5 times the layer thickness. The tapered section shall be removed before surfacing is recommenced and a joint
formed in accordance with Clause A9.1.7.7.
All costs involved in the provision and removal of these temporary ramps shall be deemed to be included in the rates tendered for the relevant
asphalt pay item.
A9.1.7.11 Surfacing of bridge decks

The type and nominal thickness of the surfacing shall be as specified in the Contract Documentation.
Before commencing with the construction of the surfacing, the actual levels of the bridge deck shall be determined by means of accurate leveling.
The levels and grades to which the surfacing is to be constructed shall be as shown on the drawings or as indicated by the Engineer. If the levels
of the concrete deck, as constructed by the Contractor deviate by more than the specified tolerances from the specified levels, he shall construct
a leveling layer at his own cost. The nominal mean maximum particle size of the aggregate in the leveling layer shall be 10 mm.
A9.1.7.12 Asphalt temperature before opening to traffic

Newly paved asphalt shall not be opened to traffic until its surface temperature, as measured using a digital thermometer, has decreased to 50oC
or less.
A9.1.8 WORKMANSHIP
The onus shall be on the Contractor to consistently construct all elements conforming to the specifications and within allowable tolerances. The
Engineer shall continuously monitor the quality and consistency of work produced by means of visual inspection as well as by appropriate testing
and evaluation of results.
in this Chapter or in Chapter 20 as relevant.
A9.1.8.1 Dimensional tolerances – new construction

The completed sections of asphalt base and surfacing shall comply with the requirements for grade, width, thickness and cross section as stated
below.
a) Level and grade
The level tolerances shall be as follows:
H90 ± 15 mm
Hmax ± 20 mm
Deviation from the specified longitudinal grade due to deviations from the specified levels shall not exceed the values given in Table A9.1.8-1.
Table A9.1.8-1: Maximum Deviation from Specified Grade
Length of deviation of grade (m) Maximum variation from specified grade (%)
2 0,354
5 0,224
10 0,158
20 0,112
30 0,091
In the case of surfacing bridge decks, the difference in level between the new asphalt and any existing adjacent bridge joint or nosing shall not
exceed 3,0 mm
b) Width
The average width of both asphalt base and surfacing shall be at least equal to that shown on the drawings and nowhere shall the outer edge of
the layer be inside the lines shown on the drawings by more than 15 mm for both asphalt base and asphalt surfacing layers.
c) Thickness
The thickness tolerances shall be as listed in Table A9.1.8-2.
Table A9.1.8-2: Thickness Tolerances
Allowable Tolerances Asphalt Base (mm) Asphalt Surfacing (mm)
D 90 15 5
D Maximum 20 8
D Average 5 2

Thickness shall be determined from carefully controlled levels taken before and after construction in exactly the same position and/or from cores
drilled from the completed layer.
d) Cross section
When tested with a 3,0 m straight edge laid at right angles to the road centerline the surface shall not deviate from the bottom of the straight-edge
by more than 6,0 mm for freeways and more than 10 mm for other roads.
At any transverse section the difference in level between any two points shall not vary from that computed from the cross section shown on the
drawings by more than 15 mm for freeways and 20 mm for other roads.
A9.1.8.2 Dimensional tolerances – overlays

Where asphalt is being placed for the purposes of rehabilitation or overlays, the following requirements shall be applicable, as relevant:
a) When the overlay is constructed to specified levels on a layer that has also been constructed or milled to specified levels by the Contractor,
all the tolerance requirements of Clause A9.1.8.1 shall be applicable.
b) When the overlay is constructed to specified levels on an existing layer, or on a layer which has been constructed or milled by the Contractor,
but which has not been constructed, or milled, to specified levels, all the tolerance requirements of Clause A9.1.8.1 shall be applicable,
except for Clause A9.1.8.1c), which relates to thickness.
c) When the overlay is not constructed to specified levels, the following tolerances shall apply:
The outer edges of the overlay shall nowhere be more than 15 mm inside or outside the lines shown on the drawings, or existing surface, and
shall be parallel to the road centre line.
The minimum thickness shall be the specified nominal thickness.
The maximum thickness shall be the specified nominal thickness + 10 mm.
In the case of surfacing bridge decks, the difference in level between the new asphalt and any existing adjacent bridge joint or nosing shall not
exceed 3,0 mm
A9.1.8.3 Construction joints

All joints shall be cut back by at least the minimum of the layer thickness constructed. When measured with a 3,0 m straight edge at 10 m intervals
longitudinally, and at 1,0 m intervals transversely, the level of the outer edge of the layer constructed shall not deviate by more than 2,0 mm from
the level plane on 80 % of the measurements. In no instance shall the difference in level differ by more than 4,0 mm on base layers and 3,0 mm
on surfacing layers. If these requirements are not met, the Contractor shall recut the joints, at his cost, in order to meet this specification.
A9.1.8.4 Surface regularity

a) Measured using inertial laser profilometers
For the lanes and surfaced shoulders wider than 2,0 m of the through road as well as interchange ramps and cross roads, the roughness of the
surfacing will be determined by using an inertial laser profilometer as specified in Chapter 20, and capable of producing a Class 1 vertical
measurement resolution, and a Class 3 longitudinal sampling distance as defined in ASTM standard (E950-09).
Surface shoulders less than 2,0 m wide, will be assessed according to measurements obtained from the adjacent trafficked lane.
The inertial laser profilometer shall be used to record the longitudinal profile in both wheel tracks (which shall be 1,75 m apart) of each traffic lane
or shoulder wider than 2,0 m, as determent according to the final line markings that will be applied after construction. Should the two tracks not
be measured simultaneously during the same pass, then procedures shall be implemented to ensure that the longitudinal profile data recorded
for the two wheel tracks are at the same longitudinal profile data recorded for the two wheel tracks are at the same longitudinal location on the
road.
The measured longitudinal profiles will then be processed using the Quarter-Car simulation model with parameter values as defined in ASTM
standard (E1170-97) for Ride Meter-Vehicle Mounted. The simulated suspension mentioned will then be linearly accumulated and divided by the
length to yield 100 m IRI (International Roughness Index) values in units of mm/m or m/km for each wheel track. The last 50 m, and the joining
first 50 m of adjacent sections will be evaluated as a 100 m section in the direction of vehicle travel. For each measured land the left and the right
100m IRI values from the three runs will then be averaged to produce the Average IRI as follows:
Run1 IRI100m Ave = (100m IRI Left wheel track + 100m IRIRight wheel track ) / 2
Average IRI100m = (Run1 IRI 100m Ave + Run2 IRI 100m Ave + Run3 IRI 100m Ave ) / 3
The Average IRI100m values is then evaluated and judged according to Table A9.1.8-3 to determine whether the 100m section needs corrective
work or payment adjustments.
The applicable Full Payment Bracket in Table A9.1.8-1 (Where value = 1.000) for the measured lanes and shoulders will be determined as follows:
Calculate the applicable Target IRI100m Ave for full payment as follows: Target IRI100m Ave = greater of 1.05 or [IRI100m Ave * {1-(NAT/100)}]
Where:
IRIb Ave = Average IRI100m before the construction of the asphalt surfacing as determined from:
The Average IRI100m , as calculated from the network roughness measurements performed by Employer not more than 12 months prior to
commencement of the contract, or
The Average IRI100m as calculated from the measurements performed as part of the assessment of the base as per Clause A5.3.8.5c) of Chapter
5 for granular bases.
NAT = Total New Asphalt Surface Thickness (measured in mm) applied over a section as part of this contract. For example, should 40 mm AC
be applied followed by 18 mm UTFC, then NAT = 58 mm.

Using the Target IRI100m Ave calculated under 1 above, find the matching Target IRI100m Ave range in the first column of Table A9.1.8-3 into which
the value fits. Then read horizontally to the relevant Payment Bracket column in which the unit value (1.000) appears, as indicated by the
highlighted cells in the Table. The values in this column shall then be applied as the payment adjustment factors for the contract or section. For
example, should the Target IRI100m Ave be 1.33, then the Payment Bracket will be No 4.
Should the Total New Asphalt Thickness (NAT) vary over the contract length, then a Payment Bracket will need to be calculated for each of these
uniform NAT sections.
Any adjustment in the payment for asphalt surfacing will be made by multiplying the full payment value for each 100 m section, (for all the relevant
payment items for this work) by the payment adjustment factor derived from Table A9.1.8-3. The payment adjustment shall apply to the total
asphalt layer width placed during a single pass by the paver over the 100 m sections in question.
Surfaced shoulders less than 2,0 m wide will be assumed to have the same roughness measurements as the adjacent lane and the quantity of
material in the shoulder shall be added to the quantity of material of the adjacent lane for determination of the payment adjustment factor.
On sections where the Average IRI100m is worse than the cut-off value listed in Table A9.1.8-3 the section is rejected and corrective work shall be
necessary.
Any corrective work required shall be made by the removal, through milling of the total asphalt layer width placed during a single pass of the paver
over the 100 m section in question, followed by reinstatement. Corrective work shall not commence until the Engineer has approved the
Contractor’s method statement. If the Contractor proposes any other corrective procedure, he shall apply to the Engineer for the Employer’s
approval of his proposal. Corrective work shall be done at the Contractor’s expense and shall be completed prior to determining pavement
thickness. After completion of the corrective work, the 100 m sections shall be re-evaluated according to the abovementioned procedure.
The longitudinal profile and the 100 m International Roughness Index (IRI) values shall be determined using a profilometer furnished and operated
by the Contractor or on his behalf in the presence of the Engineer. Prior to using the inertial laser profilometer it shall have successfully completed
a validation trial against the Instrument of Reference (Face Dipstick®) used by the Employer.
As an absolute minimum, measurements shall be provided to the Engineer after 10 %, 50 % and 100 % of the surfacing area of the project has
been completed. The Contractor will be paid for these measurements under the relevant payment item in the Part C: Measurement and Payment.
No additional payment will be made to the Contractor for additional measurements and analysis of profiles.
Table A9.1.8-3: Payment adjustment factors for asphalt surfacings
Target PAYMENT ADJUSTMENT FACTORS
𝐈𝐑𝐈𝟏𝟎𝟎𝐦 𝐀𝐯𝐞 Payment Payment Payment Payment Payment Payment Payment Payment
(m/km) Bracket 1 Bracket 2 Bracket 3 Bracket 4 Bracket 5 Bracket 6 Bracket 7 Bracket 8
< 0,80 1,050 1,050 1,050 1,050 1,050 1,050 1,050 1,050
0,81 to 0,90 1,025 1,050 1,050 1,050 1,050 1,050 1,050 1,050
0,91 to 1,00 1,010 1,025 1,050 1,050 1,050 1,050 1,050 1,050
1,01 to 1,10 1,000 1,010 1,025 1,050 1,050 1,050 1,050 1,050
1,11 to 1,20 0,990 1,000 1,010 1,025 1,050 1,050 1,050 1,050
1,21 to 1,30 0,975 0,990 1,000 1,010 1,025 1,050 1,050 1,050
1,31 to 1,40 0,955 0,975 0,990 1,000 1,010 1,025 1,050 1,050
1,41 to 1,50 0,930 0,955 0,975 0,990 1,000 1,010 1,025 1,050
1,51 to 1,60 0,900 0,930 0,955 0,975 0,990 1,000 1,010 1,025
1,61 to 1,70 0,865 0,900 0,930 0,955 0,975 0,990 1,000 1,010
1,71 to 1,80 Reject 0,865 0,900 0,930 0,955 0,975 0,990 1,000
1,81 to 1,90 Reject Reject 0,865 0,900 0,930 0,955 0,975 0,990
1,91 to 2,00 Reject Reject Reject 0,865 0,900 0,930 0,955 0,975
2,01 to 2,10 Reject Reject Reject Reject 0,865 0,900 0,930 0,955
2,11 to 2,20 Reject Reject Reject Reject Reject 0,865 0,900 0,930
2,21 to 2,30 Reject Reject Reject Reject Reject Reject 0,865 0,900
2,31 to 2,40 Reject Reject Reject Reject Reject Reject Reject 0,865
> 2,41 Reject Reject Reject Reject Reject Reject Reject Reject
On all road sections and in areas where the use of a profilometer is not possible, the rolling straight-edge, or 3,0 m, specification, as indicated
below, shall apply.
b) Using a rolling straight-edge.
When the number of surface irregularities measured in accordance with Chapter 20 shall not exceed those given below (applicable to base and
surfacing)
(i) Average number of irregularities per 100 m equal to or exceeding the specified value when taken over 300 m – 600 m lengths:
Freeways (3,0 mm irregularities)
Asphalt with rolled-in chippings 5

Stone-mastic asphalt 4
Other asphalt layers 3
Other roads (5,0 mm irregularities)
(ii) Number of irregularities equal to or exceeding the specified value when taken over 100 m sections:
Freeways (3,0 mm irregularities)
Stone-mastic asphalt 6
Other roads (5,0 mm irregularities)
c) Three metre straight edge
The maximum value of any individual irregularity when measured with a 3,0 m straight-edge laid parallel to the road centre line and measured
continuously in the individual wheel paths shall be:
Freeways
Asphalt surfacing 4,0 mm
Asphalt base 5,0 mm
Other roads 8,0 mm
d) Surfacing of bridge decks
The completed surfacing shall comply with the requirements for base layers as specified in Chapter 5 in respect of surface tolerance for grade,
smoothness, cross section and width.
A9.1.8.5 Grading
The combined aggregate and filler grading during production shall not deviate from the approved target grading by more than the tolerances given
in Table A9.1.8-4. The mean grading of each lot of the working mix (minimum of 6 tests per lot) shall be determined from samples obtained in a
stratified random sampling procedure. Consistent non-conformance to these limits shall require a new design process to be undertaken.
Table A9.1.8-4: Combined aggregate grading tolerances for sand skeleton mixes
Size of aggregate passing Permissible deviation from target grading (%) for NMPS
sieve size (mm)
7.1 mm 10 mm 14 mm 20 mm
28 0 0 0 0
20 0 0 0 ±5
14 0 0 ±5 ±5
10 0 ±5 ±5 ±5
7,1 ±5 ±5 ±5 ±5
5 ±4 ±4 ±4 ±4
2 ±4 ±4 ±4 ±4
1 ±4 ±4 ±4 ±4
0,600 ±4 ±4 ±4 ±4
0,300 ±3 ±3 ±3 ±3
0,150 ±2 ±2 ±2 ±2
0,075 ± 1* ± 1* ± 1* ± 1*
*When Statistical methods are applied the permissible deviation for the 0,075 mm fraction is ± 2 %.
For open and gap graded mixes the permissible deviation from target grading for the combined aggregate in the mix shall be as specified in the
Contract Documentation or if not specified, then the guidelines in Manual 35 and the applicable Sabita Manuals shall apply, e.g. Manual 17 for
open graded mixes, Manual 19 for bitumen rubber mixes and Manual 33 for EME. Stone skeletal mixes and SMA shall follow the guidelines in
Manual 35.
A9.1.8.6 Spread rate of rolled-in chippings

The tolerance for the spread rate of rolled-in chippings shall be ± 10 % of the specified spread rate as determined from the trial section.
A9.1.8.7 Voids
The void content of the mix shall be within the limits specified in the statistical judgment scheme in Clause A20.1.7.5d) of Chapter 20.

A9.1.8.8 Sampling
a) Component and mix sampling
Sampling of aggregates, bitumen and manufactured asphalt mix for testing shall be in accordance with the relevant methods prescribed in TMH
5: Sampling Methods for Road Construction Materials.
b) Coring of completed layers
If required in the Contract Documentation, the Contractor shall provide suitable coring machines capable of cutting 100 mm or 150 mm diameter
cores from the completed asphalt layers. The Contractor will be paid in accordance with item C9.1.13 for cutting cores ordered by the Engineer.
The cost of extracting cores for process control shall be included in the Contractor's prices for the construction of asphalt pavement layers and
will not be paid for separately. The coring equipment, traffic accommodation requirements and associated procedures must be approved by the
Engineer.
Should the Contractor does not adhere to the approved program, the Engineer may temporarily suspend the paving operations.
All core holes shall be neatly repaired with asphalt and compacted to the specified density. Wherever possible the cores shall be filled with the
same mix as used for the layer tested.
A suitable coring machine shall be available on a daily basis when asphalt paving is taking place. Cores shall only be drilled when the road
temperature is 20°C or less. Core holes shall be filled with hot mix asphalt and compacted, all within 24 hours of the core being drilled. Cores
shall be extracted within 48 hours after the paving has been completed and supplied to the Engineer.
c) Routine inspection and tests
Routine inspection and tests will be carried out by the Engineer to determine the quality of the materials and workmanship for compliance with the
requirements of this Chapter.
Test results and measurements shall be assessed in accordance with the provisions of this chapter as well as the applicable statistical judgment
principles specified in Clause A20.1.7 of Chapter 20.
Notwithstanding the requirements specified above, during assessment of the trial section, and during normal production, cores shall be regularly
extracted from the compacted layer immediately adjacent to the longitudinal joint after trimming of the edge. If the asphalt in this area indicates a
compaction level below that specified, then that area of lot shall be assessed as a separate lot to confirm full compliance with the required
compaction over the full width of the mat.
The Contractor shall keep accurate records of:
- The position where every truckload of asphalt is paved (stake value, lane, date and time).
- The temperatures of the asphalt in the trucks both at the mixing plant and at the paving equipment immediately prior to discharging the load
into the paver.
- The truck and load number from which test samples are taken. All samples taken shall be appropriately labelled and submitted to the
Engineer for further testing and assessment.

B9.1 ASPHALT LAYERS
CONTENTS
B9.1.1 SCOPE
B9.1.2 DEFINITIONS
B9.1.3 GENERAL
B9.1.5 MATERIALS
B9.1.8 WORKMANSHIP
B9.1.1 SCOPE
This Section covers the labour enhancement activities associated with the placing of asphalt layers as specified in Part A.
B9.1.2 DEFINITIONS
Definitions as provided in A9.1.2 shall apply.
B9.1.3 GENERAL
Any activity specified in Part A, where hand work is given as an alternative, shall be executed in such a way as to optimise labour.

B9.1.5 MATERIALS

The use of light equipment shall be evaluated during trial sections.

The scope for labour enhancement associated with asphalt surfacing, may be the preparation activities (sweeping, watering and protection
of kerbs and roadside furniture) and the placing of the asphalt in appropriate areas, suc h as driveways, parking areas, sidewalks and lower
order streets.
The mixing and supply of the various mix-types (HMA, WMA, recycled and reclaimed) will be in accordance with the specifications in Part A.
Certified asphalt mix-types must be manufactured, supplied and placed as determined by the certification agency
The Contractor shall prepare and submit a method statement of how the work will be executed. At least the following aspects must be dealt
with:
a) Construction Equipment
- Tools and guides required to achieve the specified dimensions and tolerances (thickness, surface regularity, compaction)
- Roller Type
- Protection Wear
b) Work Force
- Size of the workforce
- Required skill levels

c) Execution of the Works
- Spreading technique
- Rolling pattern
- Jointing
B9.1.8 WORKMANSHIP

C9.1 ASPHALT LAYERS
(i) Preamble
otherwise stated.
Any prime cost or provisional sums shall be paid in accordance with the provisions of the Conditions of Contract. The charge or mark-up tendered
None.
pay items.
km.
C9.1.1 Asphalt mix designs
C9.1.1.1 Stone skeletal mixes:
(a) Continuously graded base or surfacing (state binder type and level of design). Lump sum
(b) High modulus asphalt (EME) (state binder type and level of design) Lump sum
(c) Stone Mastic Asphalt (SMA) (state binder type) Lump sum
(d) Ultrathin Friction Courses (UTFC) (state binder type). Lump sum
(e) Porous asphalt (state binder type). Lump sum
(f) Bitumen rubber open and gap graded mixes (state mix type) Lump sum
(g) Other – as stated and defined in the Contract Documentation Lump sum
C9.1.1.2 Sand skeletal mixes:
(a) Continuously graded base or surfacing (state binder type and level of design). Lump sum
(b) Semi-gap graded mixes (state binder type and level of design) Lump sum
(c) Gap graded mixes (state binder type and level of design). Lump sum

(d) Sand asphalt (state binder type and level of design) Lump sum
(e) Other (as stated and defined in the Contract Documentation) Lump sum
The unit of measurement shall be the Lump Sum for the design of each asphalt mix type specified. The design methodology, and or level of
design, shall be as stated in the Contract Documentation. The rate tendered shall include for all costs associated with producing a laboratory as
well as a plant mixed design, verified and accepted by the Engineer after completion of the trial section.
C9.1.2 Construction of trial sections

C9.1.2.1 Asphalt layers (state mix type, layer thickness and placing technique (hand/paver)) square metre (m²)
C9.1.2.2 Removal of trial section where so instructed by the Engineer. square metre (m²)
The unit of measurement for C9.1.2.1 shall be the square metre of asphalt placed in an approved trial section constructed for each mix type
specified. The tendered rate shall include for all costs associated with constructing the trial in order for the Engineer to assess the in-place
properties of the layer prior to commencing with permanent works. Assessment of the trial shall be as described in Clause A9.1.3.3. Any additional
trial sections required as a result of the final product not meeting all the specified requirements shall not be subject to additional payment.
The unit of measurement for C.9.1.2.2 shall be the square metre of trial section removed to an approved site and the area reinstated as required.
C9.1.3 Application of bond coat
C9.1.3.1 Stable –grade 30 % net bitumen emulsion as specified. Applied with a calibrated distributer litre (ℓ)
C9.1.3.2 Applied in restricted areas using a portable pressure sprayer litre (ℓ)
C9.1.3.3 Applied by hand using brushes on all exposed transverse and longitudinal construction joints litre (ℓ)
C9.1.3.4 Other: (state type, such as standard, modified emulsion, “trackless”, Agrément certified, or litre (ℓ)
heated if applied for night work)
The unit of measurement shall be the litre of bond coat appropriately applied as specified in Clause A9.1.5.7. The tendered rate shall include full
compensation for procuring and applying the specified bond coat in the relevant applications. Payment for applications in restricted areas shall
only be made when application by means of a calibrated distributer is impractical.
C9.1.4 Asphalt base
C9.1.4.1 New Construction

(a) Stone skeletal mix – continuously graded as defined (state layer thickness, binder type and square metre (m²)
design class/ level and placing technique)
(b) Stone skeletal mix – High Modulus (EME) as defined (state layer thickness, binder type, square metre (m²)
(c) Sand skeletal mix – continuously graded as defined (state layer thickness, binder type, square metre (m²)
(d) Any of the above mix types where the use of reclaimed asphalt has been specified (indicate square metre (m²)
maximum % reclaimed asphalt or binder replacement limits)
(e) Any mix certified for specific applications by an approved agency as being fit for the purpose square metre (m²)
and as specified in the Contract Documentation.
In all cases state placing technique (hand/paver)
C9.1.4.2 Rehabilitation
(a) Stone skeletal mix – continuously graded as defined (state layer thickness, binder type and ton (t)
design class/ level)
(b) Stone skeletal mix – High Modulus (EME) as defined (state layer thickness, binder type and ton (t)
(c) Sand skeletal mix – continuously graded as defined (state layer thickness, binder type and ton (t)
(d) Any of the above mix types where the use of reclaimed asphalt has been specified (indicate ton (t)
(e) Certified: any mixes certified for specific applications by an approved agency as being fit for ton (t)
the purpose and as specified in the Contract Documentation.

Item Description
Unit
C9.1.5 Asphalt surfacing
C9.1.5.1 New construction

(a) Stone skeletal mix – continuously graded as defined (state layer thickness, binder type and square metre (m²)
(b) Stone skeletal mix – SMA as defined (state layer thickness, binder type) square metre (m²)
(c) Stone skeletal mix - open graded as defined (state layer thickness and binder type) square metre (m²)
(d) Stone skeletal mix- gap graded as defined (state layer thickness and binder type) square metre (m²)
(e) Sand skeletal mix – continuously graded as defined (state layer thickness, binder type, square metre (m²)
(f) Semi gap mix – as defined (state layer thickness, binder type and design level) square metre (m²)
(g) Sand skeletal mix – gap graded mix (state layer thickness, binder type design class/level) square metre (m²)
(h) Any of the above mix types where the use of reclaimed asphalt has been specified (indicate square metre (m²)
(i) Certified: any mixes certified for specific applications by an approved agency as being fit for square metre (m²)
C9.1.5.2 Rehabilitation
(a) Stone skeletal mix – continuously graded as defined (state layer thickness, binder type and ton (t)
ton (t)
(b) Stone skeletal mix – SMA as defined (state layer thickness, binder type)
ton (t)
(c) Stone skeletal mix – gap graded as defined (state layer thickness and binder type)
ton (t)
(d) Stone skeletal mix- open graded as defined (state layer thickness and binder type)
(e) Sand skeletal mix – continuously graded as defined (state layer thickness, binder type, ton (t)
ton (t)
(f) Sand skeletal mix – gap graded mix (state layer thickness, binder type design class/level)
(g) Any of the above mix types where the use of reclaimed asphalt has been specified (indicate ton (t)
(h) Certified: any mixes certified for specific applications by an approved agency as being fit for ton (t)

The unit of measurement for payment items C9.1.4.1 and C9.1.5.1 shall be the square metre of asphalt constructed to the specified dimensions.
The tendered rate shall include full compensation for producing the mixture, constructing the layer, process control testing as well as protection
and maintenance as specified.
The unit of measurement for payment items C9.1.4.2 and C9.1.5.2 shall be a ton of asphalt placed at the specified compacted thickness. The
tendered rate shall include full compensation for producing the mixture, constructing the layer, process control testing as well as protection and
maintenance as specified. The quantity shall be determined by means of certified weighbridge tickets issued in respect of the asphalt mix used.
No payment shall be made for excess width and wastage of asphalt, including material cut back of joints, and the mass of such excess or wasted
material shall be deducted from the recorded delivery for payment purposes. In addition, layers constructed in terms of items C9.1.4.2 and
C9.1.5.2, no payment shall be made for asphalt in excess of the mean spread rate(s), which shall be determined as follows:
1000
S = m²/ton where,
AXB
S = Mean spread rate in m²/ton

A = Average bulk relative density achieved on the road in ton/m³
B = (specified asphalt thickness in mm) + 5,0 mm
Where recycled asphalt has been prescribed, the percentage reclaimed asphalt to be incorporated, or limits to the binder replacement percentage,
shall be as specified in the Contract Documentation. The reclaimed asphalt shall be milled, crushed, screened and stockpiled in accordance with
the latest requirements of TRH 21: Recycling of Asphalt Pavements. The tendered rate for recycled asphalt shall include full compensation for
supplying the new materials, taking reclaimed asphalt from appropriately processed stockpiles, blending the materials in accordance with the
required final binder and mix properties as specified in the Contract Documentation. It shall also include producing the mix, constructing the layer,
process control tests, as well as protection and maintenance of the works, all complete as specified. No extra payment will be made for small
quantities of recycled asphalt.

C9.1.6 Extra over pay items C.9.1.4.1 and C.9.1.5.1 for placing small quantities of asphalt of ton (t)
less than 10 tons specially produced as specified in terms of Clause A9.1.7.1d)
The unit of measurement shall be the ton of asphalt of a specific type and composition, less than 10 tons of which is produced on occasion, as
specified, and measured in accordance with certified weighbridge tickets issued in regard to the mix type used.
The tendered rate shall be paid as extra over rates tendered for the relevant payment items listed above and shall include full compensation for
all additional costs to produce and place small quantities of asphalt on instruction of the Engineer.
C9.1.7 Placing and compacting asphalt in restricted areas

C9.1.7.1 Extra over payment items C9.1.4.1 and C9.1.5.1 (State layer thickness, mix class, binder square metre (m²)
type, nominal maximum particle size and placing technique (hand/paver))
C9.1.7.2 Extra over payment items C9.1.4.2 and C9.1.5.2 (State layer thickness, mix class, binder ton (t)
type, nominal maximum particle size and placing technique (hand/paver))
Items C9.1.7 are applicable solely to work that has to be executed in a restricted area of which the width is less than 1,5 m and the length is less
than 100 m.
C9.1.8 Surfacing of bridge decks

C9.1.8.1 Levelling course: Continuously graded ton (t)
(State mix type (stone or sand skeletal), binder type and nominal maximum particle size)
C9.1.8.2 Surfacing ton (t)

(State layer thickness, mix type (stone or sand skeletal), binder type, nominal maximum
particle size and placing technique (hand/paver)))
The unit of measurement shall be the ton of surfacing completed to the nominal thickness specified and measured according to certified
weighbridge tickets issued in respect to the actual mix used.
The tendered rate shall include full compensation for procuring, and furnishing of all materials, manufacturing of the asphalt, transport, placing
and finishing to the tolerances specified.
Rolled in chippings shall be paid for separately under payment item C9.1.10 as applicable

Application of rolled in chippings (State nominal size)
C9.1.9
C9.1.9.1 By means of chip spreader square metre (m²)
C9.1.9.2 By hand in restricted areas square metre (m²)
The unit of measurement shall be the ton of specified size of rolled-in chippings applied at the approved application rate, measured loose in
hauling vehicles. The tendered rate shall include full compensation for the procuring, furnishing, pre-coating, spreading and rolling in of the
chippings and for any additional costs resulting from the construction of the asphalt surfacing with rolled-in chippings.
C9.1.10 Variation rates

C9.1.10.1 Bitumen (state type) ton (t)
C9.1.10.2 Aggregate ton (t)
C9.1.10.3 Active filler (lime unless stated in Contract Documentation, or determined with mix design) ton (t)
C9.1.10.4 Cellulose fibre (state type) ton (t)
C9.1.10.5 Rolled-in chippings ton (t)
C9.1.10.6 Bituminous bond coat – net bitumen (state type) ton (t)
The unit of measurement in respect of increases or decreases of any component of the approved mix from that specified in the nominal proportions
specified for the relevant mix type, shall be the ton. No payment shall be made for inert filler added by the Contractor.
Payment for variations shall be made as specified in Chapter 1.

C9.1.11 Asphalt warm mix technology – extra over/under rate
C9.1.11.1 New construction square metre (m²)
C9.1.11.2 Rehabilitation ton (t)

The incorporation of warm mix technology shall be a prescribed in Clause A9.1.4.2. The unit of measurement shall be the extra over/under rate
tendered for any specific asphalt mix type as specified for the relevant unit listed. This rate shall only be applicable if the incorporation of warm
mix technology has been specifically prescribed in the Contract Documentation. Any incorporation of such technology initiated by the Contractor
shall not be applicable to this payment item and shall be deemed to be included in the relevant asphalt rates as tendered.
C9.1.12 Asphalt reinforcing - complete (State type) square metre (m²)

The unit of measurement shall be a square metre of asphalt covered with reinforcing placed, complete as specified and accepted by the Engineer.
The tendered rate shall include full compensation for procuring, providing, placing and fixing all materials (irrespective of the quantity of reinforcing
required), overlapping and cut-offs included, and for all transport equipment, tools, labour, supervision and all other costs necessary for installing
and protecting the reinforcing until the asphalt bond coat has been placed. The tendered rate shall also include full compensation for all special
preparatory work required. If it is necessary to repair cracks in the underlying seal or asphalt layer, separate payment shall be made therefore
under the appropriate payment items.
C9.1.13 Coring of asphalt layers
C9.1.13.1 100 mm diameter number (No)
C9.1.13.2 150 mm diameter number (No)

The unit of measurement shall be the number of cores drilled, irrespective of depth of core, and recovered as instructed by the Engineer for his
own testing. No separate payment shall be made for cores drilled as part of the Contractor's obligations under process control, the cost of which
shall be included in the prices tendered for the various items of asphalt paving.
The tendered rate shall include full compensation for drilling the cores as directed, for all plant, fuel, labour and other incidentals necessary and
for repairing the holes with a similar mix as paved. The tendered rate shall also include for any traffic accommodation measures as may be
necessary in order to extract the cores and reinstate the core holes.
C9.1.14 Surface regularity testing as described in Clause A9.1.8.4

C9.1.14.1 Establishment of equipment: (specify type) number (No)
Inertial laser Profilometer
Other Profilometer type, e.g. ARRB Walking or Face Dipstick
C9.1.14.2 Profiler Surveys utilising equipment as specified - Base layers and surfacing layers lane kilometre (km)
The unit of measurement for item C9.1.14.1 shall be the number of times the particular piece of equipment is established and de-established on
site to perform acceptance control measurements, as approved by the Engineer, and shall include full compensation for providing and establishing
the equipment on site and subsequent de-establishing of the equipment from site when no longer required.
The unit of measurement for item C9.1.14.2 all be the kilometre of road surveyed in accordance with, and as specified in Clause A9.1.8.4 and
shall include full compensation for surveying the specified layer, and for analysing and determining the longitudinal profiles and 100 m International
Roughness Index (IRI), all as specified. The tendered rate shall also include full compensation for the number of runs per lane as specified.
C9.1.15 Milling of bridge decks and keys adjacent to bridge decks
C9.1.15.1 Provision of an appropriate sized milling machine number (No)
C9.1.15.2 Milling of bridge decks and keys to bridge deck approaches cubic metre (m³)
C9.1.15.3 Cleaning of milled surfaces square metre (m²)

The lump sum tendered under payment item C9.1.15.1 shall include full compensation for establishing an appropriate sized milling machine on
site, irrespective of the number of establishments required.
The rate tendered under payment item C9.1.15.2 shall include full compensation to mill off existing asphalt on bridge decks or to mill an appropriate
keyway into existing pavement layers at the approach to bridge decks. The rate shall include for milling and subsequent disposal of the milled
material to an approved spoil site.
The rate tendered under payment item C9.1.15.3 shall include full compensation for cleaning the milled areas of all loose material and prepare
the surface prior to the application of the bond coat as specified.

C9.1.16 Work undertaken in accordance with a Product Performance Guarantee System
C9.1.16.1 Provision of a Performance Guarantee Lump sum
C9.1.16.2 Construction of pavement layer (indicate layer/s) square metre (m²)

The tendered lump sum under payment item C9.1.16.1 shall include full compensation for the cost of appointing a competent designer, carrying
out additional tests and for the provision of a bank guarantee in respect of the road pavement structure the value of 10 % of the Contract Value,
valid for the period prescribed in the Contract Documentation.
The tenderer shall, with his tender, provide documentation to confirm that a design performance guarantee as required shall be provided by an
acceptable financial institution should the tender be successful. The performance guarantee as required shall be submitted to the Employer by
the successful Contractor before signing of the contract including the applicable date of commencement of validity of the guarantee stated to be
from the Taking-over Certificate and its estimated date.
The guarantee shall be prepared in accordance with the format provided in the Contract Documentation. The terms and conditions applicable to
the release of the performance guarantee shall be as described in Clause D9.1.3 in Part D of this Chapter.
The tendered lump sum shall not be subject to Contract Price Adjustment and shall become payable once the Contractor has submitted and the
Employer has accepted the guarantee.
The rate tendered under payment item C9.1.16.2 shall include all costs associated with constructing the relevant pavement layers, all as specified

D9.1 ASPHALT LAYERS
CONTENTS
D9.1.1 SCOPE
D9.1.2 DEFINITIONS
D9.1.3 GENERAL
D9.1.4 DESIGN BY THE CONTRACTOR
D9.1.5 MATERIALS
D9.1.6 ASSESSMENT CRITERIA
D9.1.1 SCOPE
This Section covers the specifications related to the provision of functional and, or, structural layers of a road pavement structure comprising the
asphalt surfacing, and, or the base layer (where specified) in terms of either a design and/or a performance guarantee to be provided by the
Contractor. The duration of any such performance guarantees shall be as specified in the Contract Documentation and the issuing of a Taking-
Over Certificate for the whole of the project. It includes performance parameters, field measurements, acceptance criteria and remedial work
methodologies.
D9.1.2 DEFINITIONS
- Performance Period: The Performance Period shall be the number of years from the date of issue of the Taking-Over Certificate for the whole
of the works as specified in the Contract Documentation.
- Taking Over Certificate: As defined in the General Conditions of Contract for the project.
- Performance Certificate: As defined in the General Conditions of Contract for the project.
- Performance Guarantee Period: The performance period shall be the number of years from the date of issue of the Taking-Over Certificate
for the whole of the works as specified in the Contract Documentation.
- Performance Guarantees: Lodging of bank guarantees from an approved institution to the value and period as stated in the Contract
Documentation.
D9.1.3 GENERAL
D9.1.3.1 Extended Performance Warranty
The work shall be constructed in terms of an extended warranty as specified in the Contract Documentation. The extended warranty, in the form
of financial guarantees and in the format as prescribed by the Employer, shall be limited to the performance of the work. With the exception of
de-bonding between the asphalt layers and the substrate, the Contractor shall not be held liable for any failures that might occur as a result of
failure within the underlying layers. During the Extended Warranty Period, the Contractor shall also not be held liable for any damage to the layer/s
resulting from external sources, including, but not limited to:
a) Traffic accidents
b) Spillage of fuel, oils, hazardous materials, etc. from public vehicles
c) Materials falling off public vehicles
d) Travelling of construction/tracked plant (other than his own) after completion of the Works.
Prior to the issuing of the Taking-Over Certificate, the Contractor shall provide two guarantees, each valued at 5 % of the cost of the layer/s (as
per final constructed quantities measured under Part C of this Chapter (Measurement and Payment) for the performance of the layer/s. The
guarantees shall be issued by a bank or other institution approved by the Employer and shall become effective on issue of the Taking-Over
Certificate. They shall remain valid until released in terms of Table D9.1.3-1 and/or as specified in the Contract Documentation.

The program for the release of the guarantees shall be as follows:
Table D9.1.3-1: Program of release of guarantees
Time Activity
Provision of two guarantees (5 % & 5 %)
Completion of Works and issue of the Taking-Over Certificate
Payment of 50% of retention (as per the relevant GCC)
Payment of balance of retention to be released upon
Acceptable performance of Works one year after issuing of
issuing of Performance Certificate (as defined in the
the Taking-Over Certificate
GCC relevant to the Project)
Acceptable performance of layers (number of years as
defined in the Contract Documentation) after issuing of the Release of 1st guarantee (5%)
Taking-Over Certificate
Acceptable performance of layers (number of years as
defined in the Contract Documentation) after issuing of the Release of 2nd guarantee (5%)
Taking-Over Certificate
D9.1.3.2 Quality Plan

Prior to commencing with any permanent works, the Contractor shall submit a Quality Plan, for acceptance by the Engineer, detailing all checks
and hold points relating to construction of the specified product.
D9.1.3.3 Nominal mix proportions

The Contractor shall determine the mix proportions based on his design/s. No variations to his nominal proportions shall be payable under this
Section.
D9.1.3.4 Trial sections

Prior to executing any permanent work, the Contractor shall conduct trial sections as described in Part A of this Chapter for the necessary
approvals. No additional payment shall be made for such trial sections.
D9.1.3.5 Weather limitations

Unless so specifically stated in Form E1: Quality Assurance and approved by the Engineer, the weather limitations as specified in Part A shall be
applicable in all instances.
D9.1.3.6 Moisture
The requirements with respect to moisture as specified in Clause A9.3.5 shall be applicable in all instances.
D9.1.3.7 Surface preparation and requirements

Unless so specifically stated in Form E1: Quality Assurance and approved by the Engineer, the requirements for surface preparation as specified
in Part A of this Chapter shall be applicable in all instances.
D9.1.4 DESIGN BY CONTRACTOR

It shall be the Contractor’s responsibility to ensure that the information provided in the Contract Documentation is sufficient in order to carry out
his own assessment of the condition of the road. The contract may carry out additional testing/assessment, after approval by the relevant road
authority, in order to ensure that there is sufficient information for him to carry out an appropriate design in order for its performance to comply
with the specified criteria.
In the event that a design is specified, the Contractor shall ensure that he has sufficient information to assess and accept the specified design and
to ensure it shall perform to the specified criteria.
In order to achieve the design, or acceptance, of the specified design, the Contractor shall appoint a competent designer. The Contractor shall
take full responsibility for the performance of the designer and no separate payment shall be made for any costs thereof, or for any additional
testing deemed necessary.
D9.1.5 MATERIALS
Unless contrary to the requirements of a certified proprietary product, the constituents shall comply with the following requirements:
D9.1.5.1 Bond coat/s

The bond/s coat shall be as stated by the tenderer (Form E1: Quality Assurance) which shall include the proposed application rate, as well as the
type and proposed percentage modifier (if any). The bond coat/s shall be applied in a continuous spray and application by means of hand spray
shall not be permitted. Where a self-priming paver is not used, the tack coat shall have such properties as to not be picked up by construction (or
other) traffic during the paving operation.
D9.1.5.2 Bituminous binders

a) Unless specifically stated in Form E1, the type of binder utilised in the mix shall conform to the relevant requirements for the selected binder
as specified in Part A of this Chapter. Should the Contractor wish to use a binder with properties different from those specified in Part A,
further details regarding the composition, test methods and acceptance criteria for such binder shall be included in the tender under Form
E1: Quality Assurance.

b) The type and percentage of anti-stripping agent (if applicable) shall be as stated in Form E1: Quality Assurance.
D9.1.5.3 Aggregates
a) The aggregates to be utilised in the mix shall comply in all respects with the relevant and appropriate requirements as specified in Part A of
this Chapter. Any deviation or amendments from these requirements shall be stated in Form E1: Quality Assurance.
b) The several aggregate fractions for the mixture shall be sized, graded and combined in such proportions that the resulting composite blend
consistently meets the required performance criteria.
D9.1.5.4 Composition of mix

The composition of the mix or mixes shall be as proposed by the tenderer in Form E1: Quality Assurance
No adjustment of compensation shall be made should the actual mix proportions used in the works vary from that nominated by the Contractor
on Form E1: Quality Assurance.
The Contractor shall submit to the Engineer his design for the asphalt mixes within thirty (30) days of the date of the Letter of Acceptance. The
target binder content, filler content and aggregate grading shall be subject to the tolerances given in Part A of this Chapter as relevant. All
production and application shall be carried out in terms of the details included under Form E1: Quality Assurance.

D9.1.6.1 Mixing plant
Unless specifically stated in Form E1: Quality Assurance, all mixing plant utilized shall comply with the relevant requirements as listed in Part A
of this Chapter.
D9.1.6.2 Paving equipment

Unless specifically stated in Form E1: Quality Assurance, all paving and compaction equipment utilised shall comply with the relevant requirements
as listed in Part A of this Chapter.

Unless specifically stated on Form E1: Quality Assurance the work shall be carried in accordance with all the relevant requirements as specified
in Part A of this Chapter in all respects.
The application rate for the bond coat shall be nominated by the Contractor for a specific area, taking account of:
- The results of sand-patch tests.

- The traffic counts for that area.
- The percentage of heavy vehicles.
- The dryness of the existing surfacing.
- Thickness of the layer being constructed
No adjustment in compensation shall apply should the actual tack coat application be higher or lower than that nominated by the Contractor.
At the approaches to exposed bridge joints the Contractor shall mill out the existing asphalt base or surfacing on the abutment side to a depth of
15 mm (or as may otherwise be prescribed) and for a distance of at least 5,0 m. The asphalt surfacing shall be placed to form a smooth transition
towards the bridge joint.
D9.1.8 QUALITY OF MATERIALS AND WORKMANSHIP

D9.1.8.1 Contractor’s obligation.
Specifications regarding workmanship as detailed in Part A of this Chapter for asphalt layers shall apply. In the event that there is a variation to
the workmanship requirements and conditions of construction, the Contractor shall clearly state this in his tender document. Failure to do this shall
result in the Contractor having to comply with all the workmanship requirements as stated in Part A.
The Contractor shall be required to submit his detailed Quality Assurance Plan to the Engineer for approval within ten (10) days of the date of the
Letter of Acceptance. Once it has been approved, the Contractor shall not deviate from it without prior written agreement with the Engineer.
The onus rests with the Contractor to produce work which conforms in quality to the Quality Assurance Plan, the specifications and requirements
herein, and to other relevant specifications and standards defined in the submitted and accepted tender (e.g. in Form E1: Quality Assurance)
The Engineer shall, however, conduct such tests as he may deem applicable and shall retain all rights as determined in the relevant Conditions
of Contract related to bad workmanship and to unacceptable materials. This shall also be applicable to the accepted layers (or design) and related
specifications.

D9.1.8.2 Permissible deviations
Notwithstanding the above the following shall also apply:
a) Working mix
The permitted deviation of the working mix from the accepted target mix proportions shall be within the limits specified in Form E1: Quality
Assurance but shall in no instance exceed the limits listed in Part A of Chapter 9.
b) Bond coat
The application of the tack coat shall be at the rates specified in Form E1: Quality Assurance: UTFC, but shall have a tolerance not exceeding ±
0,1 ℓ/m² (net cold bitumen)
c) Aggregate grading
The aggregate grading shall not deviate from the approved working mix by more than that stated in Form E1: Quality Assurance, but in no instance
deviate by more than that listed in Table D9.1.8-1 below.
Table D9.1.8-1: Deviations permitted
Aggregate sieve size (mm) Permissible deviation from target grading (%)
10 mm ± 4,0
7,1 mm ± 4,0
5,0 mm ± 3,0
2,0 mm ± 3,0
1,0 mm ± 3,0
0,600 mm ± 3,0
0,300 mm ± 3,0
0,150 mm ± 3,0
0,075 mm ± 1,5
d) Asphalt binder content

The binder content in the approved working mix shall have a tolerance as listed in Form E1: Quality Assurance, or as prescribed in Part A of
Chapter 9.
e) Layer Thickness
The mixture shall be laid at a nominal compacted thickness as specified. Increased thicknesses may come about as a result of filling ruts of less
than 10 mm depth. Tenderers shall make provision in their tendered m² rate for any additional quantities of asphalt required as a result of filling
such ruts. Existing rut depths on areas where no milling and replacement of the existing layers is envisaged shall be listed in the Contract
Documentation.
D9.1.9 ASSESSMENT CRITERIA

The performance parameters to be assessed are listed in Tables D9.1.9-1 and D9.1.9-2 for visual, instrumentally and test assessed parameters
or as otherwise prescribed in the Contract Documentation. Table D9.1.9-1 is specific for the performance of the slow lanes only in the case of a
dual carriageway, or the travelled lane in the case of a single carriageway. Table D9.1.9-2 is specific to the asphalt surfacing performance of the
shoulders and inner lanes, where applicable, on dual carriageways.
Table D9.1.9-1: Performance parameters for the slow lane of dual carriageways and the travelled lane of single carriageways
Instrumentally Assessed
Visually Assessed Parameters Test Assessed Parameters
Parameters
1. Cracking 1. Deflection 1. Air Permeability
2. Bleeding 2. Rutting 2. Water Permeability
3. Raveling 3. Roughness 3. Marvil Permeability
4. Mean Profile Depth
Table D9.1.9-2: Performance parameters for the shoulders of dual and single carriageways and inner lanes of dual carriageways
Instrumentally Assessed
Visually Assessed Parameters Test Assessed Parameters
Parameters
1. Cracking 1. Deflection 1. Air Permeability
2. Bleeding 2. Rutting 2. Water Permeability
3. Raveling 3. Roughness 3. Marvil Permeability
Cracking shall be defined as either Surface Cracking and/or Longitudinal and/or Transverse and/or Crocodile Cracking as defined in TMH9 Manual
for Visual Assessment of Road Pavements, Part A and Part B referred to in Clause A20.1.4.11 of Chapter 20.

D9.1.10 ACCEPTANCE CRITERIA
D9.1.10.1 Visual Assessments
Visual assessment shall be carried out in accordance with the requirements of TMH9 as referred to in Clause A20.1.4.11 of Chapter 20. The
visually assessed parameters as well as the calculated Combined Index Value shall meet the Acceptance Criteria listed in Table D9.1.10-1 below,
which shall be applicable at the termination of the product Performance Guarantee Period, i.e. the performance period stated from the date of the
issue of a Taking-over Certificate for the Works. Interim visual assessments shall be as specified in the Contract Documentation.
The visual assessments of the pavement during the Performance Guarantee Period shall be undertaken by means of an assessment panel
comprising the following representatives:
- Employer: 2 representatives
- Contractor: 2 representatives
- Engineer: 2 representatives
All site inspections/investigations shall be undertaken by the panel of representatives. The arrangements, responsibilities and all costs associated
with providing the necessary equipment, transport and traffic accommodation measures required to undertake the visual inspection shall be to the
cost of the Contractor. The presence of the Employer’s representatives shall be at the discretion of the Employer. The visual assessments shall
be carried out during daylight and off-peak traffic periods.
Table D9.1.10-1: Acceptance criteria for visually assessed types of distress
Maximum allowance
Type of Distress 1 CIV2
Degree
Class 1 Class 2 Class 3 Class 4 Class 5
Cracking 2 0,05 0,05 0,1 0,10 0,15
Bleeding (flushing) 2 0,1 0,1 0,1 0,15 0,2
Surface raveling 1 0,05 0,05 0,1 0,1 0,15
Notes:
1. The degree of a visually assessed parameter as specified in TMH9 Manual for Visual Assessment of Road Pavements Part A and Part B,
issued by the Committee of Transport Officials (COTO) May 2016.
2. Combined Index Value (CIV) per one kilometre length of lane or shoulder. The calculation for CIV is defined in Clause D10.1.5.3 of Chapter
10.
D9.1.10.2 Deflection
Deflection measurements shall be carried out as specified in Clause A20.1.5.5e) of Chapter 20. Where so specified in the Contract Documentation,
at the end of the Performance Guarantee Period, the structural capacity of the road pavement, as determined in terms of deflection measurements,
shall conform to be acceptance criteria presented in Table D9.1.10-2 below. The acceptance criteria is specified in terms of the maximum
deflection (Ymax), base layer index (BLI) and middle layer index (MLI) as calculated from FWD deflection measurements. Segment lengths of
1,0 km in length shall be identified for evaluation. The 90th percentile value per segment shall be used to judge acceptance.
Table D9.1.10-2: Acceptance criteria for deflection

Maximum 90th
Base type Percentile Value Class 1 Class 2 Class 3 Class 4 Class 5
(Micron)
Ymax 500 600 650 1 000 1 500
Granular (G1) BLI 190 240 250 420 800
MLI 50 75 100 160 350
Ymax 420 510 680 NR NR
Asphalt BLI 155 140 175 NR NR
MLI 30 50 100 NR NR
Ymax 450 500 600 650 NR
Bitumen
BLI 170 190 240 250 NR
Modified
MLI 40 50 75 100 NR
Ymax NR NR 440 590 1 000
Cement
BLI NR NR 85 110 290
Treated
MLI NR NR 45 90 240
Notes:
1. Class 1 to 5 are defined in TRH26 – South African Road Classification and Access Management Manual issued by the Committee of
Transport Officials Version 1.0, August 2012.
2. NR – Not Recommended
D9.1.10.3 Rutting
At the end of the Performance Guarantee Period, as determined in terms of the specified methodology, the surface deformation (rutting) as
determined shall not exceed the values as specified in Table D9.1.10-3 below for the specific road class.

Table D9.1.10-3: Specification for rut depth criteria
Maximum length (%) of Profilometer measurements: Limiting Rut Depth (mm)

segment with rut depth
worse than limiting
value
10 % 6 8 8 8 10
5% 8 10 10 10 15
0% 10 15 15 15 20
D9.1.10.4 Roughness
Roughness shall be measured in accordance with Clause A20.1.5.5c). At the end of the Performance Guarantee Period, as determined in terms
of the Specified Methodology, the surface roughness as determined in accordance with Clause A20.1.5.5c), shall not exceed the values as
specified in Table D9.1.10-4 below.
Table D9.1.10-4: Specification for roughness criteria
Maximum length (%) of Roughness measurements limiting IRI (mm)

segment with roughness
worse than limiting Class 1 Class 2 Class 3 Class 4 Class 5
value
S AC S AC S AC S AC S AC
10 % 2,2 1,8 2,5 2,0 3,0 2,5 3,6 3,0 4,4 3,5
5% 2,5 2,1 2,7 2,2 3,5 3,0 3,9 3,5 4,7 4,0
0% 2,7 2,3 3,0 2,5 4,0 3,5 4,8 4,0 5,0 4,5
Notes:
1. S – Single or Double Seal Surfacing
2. AC – Asphalt Surfacing
D9.1.10.5 Mean profile depth

At the end of the Performance Guarantee Period, as determined in accordance with Clause A20.1.5.5b), the mean profile depth as determined
shall not exceed the values as specified in Table D9.1.10-5 below.
Table D9.1.10-5: Specification for mean profile depth
Maximum length (%) of Mean profile depth (mm) for Road Class
segment with mean
profile depth worse than
limiting value
10 % 0,8 0,8 0,8 0,4 0,4

5% 0,6 0,6 0,6 0,35 0,35
0% 0,4 0,4 0,4 0,3 0,3
D9.1.10.6 Air permeability

Before issuing of the Taking-over Certificate, and at the end of the Performance Guarantee Period, the permeability of the asphalt layers, as
determined by means of the air permeability test method described in Clause A20.1.5.3c) shall conform to the acceptance criteria as specified in
Table D9.1.10-6 below.
Table D9.1.10-6: Criteria for air permeability tests acceptance

Year Limiting Air Permeability
(X10-8cm2)
0 and 5 1,0
D9.1.10.7 Water permeability

Before issuing of the Taking-over Certificate, at the end of the Performance Guarantee Period, the permeability of the asphalt layers, as determined
by means of the Water Permeability test method, as prescribed in EN 12697, shall conform to the acceptance criteria as specified in Table D9.1.10-
7 below.
Table D9.1.10-7: Acceptance criteria for water permeability tests

Year Limiting Water Permeability (X10-8cm2)
0 and 5 < 4,0 mm/s
D9.1.10.8 Marvil permeability

Before issuing of the Taking-over Certificate, and at the end of the Performance Guarantee Period, the permeability of the asphalt layers, as
determined by means of the Marvil permeability test method defined in SANS 3001-BT12, shall conform to the acceptance criteria as specified in
Table D9.1.10-8 below.

Table D9.1.10-8: Acceptance criteria for marvel permeability tests
Year Limiting Marvil permeability
0 and 5 < 1 ℓ/hour
D9.1.11 EVALUATION
The following procedures shall be followed by the Contractor to determine acceptance of the pavement by the Employer at the end of the
Performance Guarantee Period or whether earlier remedial work is required in terms of the specified acceptance criteria.
D9.1.11.1. Evaluation at the end of the Performance Guarantee Period

Should the full acceptance criteria not be met, the Employer shall advise the Contractor of such defects as may be evident and may:
a) Instruct the Contractor in writing to undertake remedial work in accordance with Clause D9.1.11.2.
b) Establish a fair valuation of the costs or damages that may be incurred due to the defective work and request payment of such amounts from
the Contractor. Once such payments have been received the Performance Guarantee shall be released to the Contractor.
c) The Contractor may elect to undertake all outstanding remedial work, which shall be undertaken in accordance with Clause D9.1.12. Upon
satisfactory completion of such remedial work and acceptance by the Employer, the Performance Guarantee shall be released to the
Contractor.
Remedial work, if applicable, shall commence within 28 days of a written order to the Contractor by the Employer. Once the conditions stated
under either a), b) or c) above have been met, the Performance Guarantee shall be released to the Contractor without prejudice to any obligations
to the Contractor with respect to Latent Defects. The Contract shall then be complete and the Contractor shall have no further liability for the
performance of the Works, except for unfulfilled obligations as provided under the relevant Clause/s of the Conditions of Contract pertaining to
the project.
D9.1.11.2 Evaluation at any time during the Performance Guarantee Period

The Employer shall be entitled to carry out an assessment of the Works at any time during the Performance Guarantee Period. Should any
parameter/s fall into the remedial-work-required category, the Employer shall inform the Contractor who shall immediately propose a solution to
rectify the problem/s and obtain the Employer’s approval and rectify the problem/s in accordance with Clause D9.1.12.2. The remedial work shall
commence within 28 days of being notified by the Employer.

D9.1.12.1 Determination of extent of work
The Contractor, in liaison with the Visual Assessment Panel and Employer, shall be responsible for determining the extent to which remedial work
is to be undertaken. Depending on the type of distress and severity thereof, further investigation and testing (e.g. test pits, etc.) may be necessary
to be undertaken by the Contractor to, not only determine the extent of the area to be repaired, but also the depth to which repairs of the pavement
structure are to be undertaken. The extent of repair work shall be agreed and confirmed with the Employer prior to commencement of any repair
work. The cost of such further investigation and testing shall be borne by the Contractor.
D9.1.12.2 Execution of work

All remedial work or repairs to the pavement structure in order to satisfy the performance requirements as specified shall comply with the following
requirements:
a) The Contractor shall, at his own cost, supply, erect and maintain the necessary temporary traffic-control signs in accordance with the
requirements in Chapter 1 or any other requirements as prescribed in the Contract Documentation with respect traffic accommodation.
b) The Contractor shall, also at his own cost, repair/reinstate such items as road studs, road markings, etc., should these be damaged or
influenced by the required remedial work.
c) The various types of remedial work contained in Table D9.1.12-1, depending on the degree of distress, shall be undertaken by the Contractor,
at his own cost, to reinstate/rectify specified defects in the pavement structure recorded during the Performance Guarantee Period.
Table D9.1.12-1: Remedial work
Acceptance
Type of Distress Minimum Remedial Measures
Criteria: Clause
Mill out full depth of defective surfacing including pavement layers, if required, and
Cracking D9.1.10. 1
reconstruct
Bleeding (flushing) D9.1.10.1 Mill out full depth of defective surface and replace surfacing
Surfacing raveling D9.1.10.1 Repair with AC or mill out full depth of defective surfacing and replace surfacing
Mill out full depth of surfacing and pavement layers to pre-determined depth and
Excessive deflection D9.1.10.2
reconstruct pavement layers and surfacing
Mill out full depth of defective surfacing including pavement layers if required, and
Rutting D9.1.10.3
reconstruct
Roughness D9.1.10.4 Mill out to pre-defined depth and replace
Mean Profile Depth D9.1.10.5 Mill out surfacing and replace
Air Permeability D9.1.10.6 Fog spray surfacing with agreed emulsion or mill out surfacing and repave surfacing
Water Permeability D9.1.10.7 Fog spray surfacing with agreed emulsion or mill out surfacing and repave surfacing
Marvil Permeability D9.1.10.8 Fog spray surfacing with agreed emulsion or mill out surfacing and repave surfacing

South Africa
COTO
Officials

Draft Standard (DS)

CHAPTER 10: SURFACE
TREATMENTS
October 2020

FOREWORD

Published by:
The document with its Chapters is provided as a Draft Standard (DS) without any warranty of any kind, expressed or implied. No warranty
or representation is made, either expressed or implied, with respect to fitness of use and no responsibility will be accepted by the
Committee or the authors for any losses, damages or claims of any kind, including, without limitation, direct, indirect, special, incidental,
consequential or any other loss or damages that may arise from the use of the document.

No part of this Draft Standard document may be modified or amended without permission and approval of the Committee of Transport
Officials (COTO). Permission is granted to freely copy, print and distribute this Draft Standard document for use by industry.
The new COTO Standard Specifications for Road and Bridge Works for South African Road Authorities was approved by COTO on 18
August 2020 as a Draft Standard (DS) and will be replacing the COLTO Standard Specifications for Road and Bridge Works for State
Road Authorities (1998 Edition).
Existing contracts and tenders in the design phases based on the COLTO Standard Specifications (1998 Edition) will remain unaffected
but will be phased out during the next 6 months and the COTO Standard Specifications (2020 Edition) will be mandatory for use in
procurement documents advertised as from 1 March 2021.
Document versions:
Draft Standard (DS). The Draft Standard will be implemented in industry for a period of two (2) years, during which written comments
may be submitted to the COTO subcommittee. Draft Standards (DS) have full legal standing.
Final Standard (FS). After the two-year period, comments received are reviewed and where appropriate, incorporated by the COTO
subcommittee. The document is converted to a Final Standard (FS) and submitted by the Roads Coordinating Body (RCB) to COTO for
approval as a final standard. This Final Standard is implemented in industry for a period of five (5) years, after which it may again be
reviewed. Final Standards (FS) have full legal standing.
Comments:
Comments on the Draft Standard Chapters should be provided in writing on the Excel spreadsheet provided on the websites mentioned
below and e-mailed to cotorevision@nra.co.za .
Please note:
The Draft Standard (DS) Chapters will be made available for download on the South African National Roads Agency SOC Ltd (SANRAL)
and Department of Transport websites.
TABLE OF CONTENTS
CHAPTER 10: SURFACE TREATMENTS......................................................................................................................... 10-1

10.1 GENERAL REQUIREMENTS FOR SURFACE TREATMENTS ................................................................................ 10-1
PART A: SPECIFICATIONS .......................................................................................................................................................................................... 10-1
PART B: LABOUR ENHANCEMENT ........................................................................................................................................................................... 10-25
PART C: MEASUREMENT AND PAYMENT................................................................................................................................................................ 10-27
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES .................................................................................................................................. 10-34
CHAPTER 10: SURFACE TREATMENTS
10.1 GENERAL REQUIREMENTS FOR SURFACE TREATMENTS
CONTENTS
A10.1.1 SCOPE
A10.1.2 DEFINITIONS
A10.1.3 GENERAL
A10.1.5 MATERIALS
A10.1.8 WORKMANSHIP

A10.1 GENERAL REQUIREMENTS FOR SURFACE TREATMENTS

A10.1.1 SCOPE
This Chapter covers all the material requirements and work in connection with the construction of surface treatments incorporating single seals, multiple
stone seals, sand seals, Cape seals, graded aggregate seals, slurry seals and microsurfacings.
A10.1.2 DEFINITIONS
Surface treatments - encompass thin bituminous surfacings applied as wearing courses for new construction or as reseals.
Bitumen - is a dark brown to black viscous liquid or solid, consisting essentially of hydrocarbons and their derivatives. It is soluble in trichloroethylene, is
substantially non-volatile, and softens gradually when heated. Bitumen is obtained by refining petroleum crude oil.
Penetration grade bitumen - is manufactured by straight-run distillation of crude oil or by blending two or more base components (one hard, such as
40/50 pen, and the other soft, such as 150/200 pen). Penetration grade bitumen is used either as a primary binder (70/100 pen for surface seal work in
South Africa) or as a base bitumen for the manufacture of cut back bitumen, modified binders or bitumen emulsions.
Bitumen emulsions - are two-phase systems consisting of a dispersion of bitumen droplets in water which contains an emulsifier. The emulsifiers are
added to assist in the formation of the emulsion, to render it stable, and to modify its properties. Different grades of emulsion are manufactured to allow
slower and faster curing e.g. stable grade (Slow setting) is required for labour intensive work and manufacturing of conventional slurries. Spray grade
(Rapid setting) emulsions are preferred for spray sealing. The terms cationic and anionic derive from the electrical charges on the bitumen globules. The
positively charged cationic emulsions are preferred for construction of sprayed seals due to superior adhesive properties with the mostly negatively
charges aggregate used for seal work in South Africa.
Cutback bitumens - are blends of penetration grade bitumen and slow, medium or rapid curing sol vents. The choice of solvent determines the rate at
which the bitumen will "set up" or cure when exposed to air. A rapid-curing (RC) solvent will evaporate more quickly than a medium-curing (MC) solvent,
which in turn will cure more rapidly than a slow-curing (SC) solvent. The viscosity of the cutback bitumen is determined by the proportion of solvent added.
MC-30 used for prime coats has a high percentage of medium curing solvent (45 %) with a very low viscosity. MC-3000 used for sprayed seal work has
approximately 12 % solvent allowing application at low road surface temperature.
Modified binders - modification is achieved by the introduction of polymers, crumb rubber, aliphatic synthetic wax or naturally occurring hydrocarbons
to a penetration grade bitumen. Modified binders for seal work are classified into:
• Hot homogeneous modified binder S-E1 and S-E2 for spray sealing and C-E1 for crack sealing (refer properties in TG1)
• Cold homogeneous modified binder SC-E1 and SC-E2 for spray sealing and CC-E1 for crack sealing
• Hot non-homogenous modified binder S-R1 and S-R2 for spray sealing and C-R1 and C-R2 for crack sealing

Aggregate for seal work consists mainly of crushed rock with specified hardness, durability, polishing resistance, adhesion to bitumen and falling within
selected grading envelopes. Screened natural gravels and sand as well as crushed slag, separated from metals during the smelting or refining of ore, are
also used with success for specific seal types.
Sprayed seals - are constructed by spraying bituminous binder, spreading of aggregate and rolling. For purpose of this document sprayed seals are
divided into sand/ grit seals, single stone seals (Including single stone and sand blinding layer), Multiple stone seals (Double or triple stone seals) and
Graded aggregate seals e.g. Otta seals.
Combination seals - are defined as seal types consisting of at least two components of different character e.g. Cape seals (Single stone seal with one or
two layers of slurry) and Slurry-bound Macadam seals.
Slurry - is a homogenous mixture consisting of fine aggregate (normally crusher dust), or where required to satisfy grading requirements and permitted, a
blend of crusher dust and a limited percentage approved natural sand, stable grade bitumen emulsion (anionic or cationic) or a polymer modified stable
grade emulsion, active filler (usually cement or lime), water, additive to retard the setting rate of rapid setting slurry) and Polymer (in case of
microsurfacings).
Tack coat - is defined as the first application of binder for a sprayed seal or a Cape seal
Penetration coat - is defined as the second application of binder on a multiple stone seal
The term cover spray - refers to the application of a diluted emulsion as a final binder application on single or double seals or before application of the
slurry, in case of Cape seals.
The term fog spray or rejuvenation spray - is used for the application of anionic emulsion, diluted anionic emulsion or invert emulsion rejuvenator for
purposes of adding additional binder to the seal or rejuvenating the seal at a later stage of the seal life. Specifications for this type of treatment are
provided in Chapter 8.
A10.1.3 GENERAL
A10.1.3.1 Requirements pertaining to all surface treatments
Adequate advance notice shall be given to the Engineer before the Contractor proceeds with any seal work. This notice shall include the program containing
exact dates and sections to be sealed as well as the stockpile/s which will be used for each section.
Seal work shall not commence until a design has been submitted for each section an approved by the Engineer.
The areas to be sealed shall be cleaned of all dust, dirt, dung, oil or any other foreign matter that may be deleterious to the seal.
Sealing work shall not commence until the Engineer has approved all preparatory works ordered on that section of road.
Unless otherwise agreed by the Engineer and subject to the outcome of a trial section, the Contractor shall programme all spraying to cease each working
day at 15:00.
The Contractor shall comply with the requirements of Chapter 1 regarding traffic over completed layers
Wherever reference is made to distance the measurements for length shall be taken as actual lengths measured along the road centreline.
All quantities of sprayed binder and variations shall be measured at spray temperature of the applied binder.

The following general limitations shall apply:
• Whenever the temperature of the road surface falls below the specified temperature for the binder to be applied or will probably fall below the
required temperature before spraying the binder, no binder shall be sprayed;
• No bituminous work shall be done during foggy or rainy weather and, when a cold wind is blowing, the above temperatures as specified in the
sub-sections below, shall be increased by 3°C to 6°C.
• When strong winds (more than 30 km/h) are blowing which are likely to interfere with the proper execution of the work, no sealing, especially
spraying of binder, shall be done;
• No sealing shall be done when rain or cold temperature is imminent;
• No sealing shall be done when the surface of the layer is visibly wet, i.e. more than damp;
• No sealing shall be done after sunset
Only emulsion products, MC3000 and cutback S-E1 binder shall be permitted during the embargo period stated in the Contract Documentation. Special
formulated winter grade binders shall only be allowed if provision is made in the Contract Documentation.
The minimum road-surface rising temperatures at which the spraying of the different types and grades of binder shall be allowed are specified in Table
A10.1.3-1.

Table A10.1.3-1: Minimum road-surface rising temperature
Bituminous binder type Minimum rising road surface
temperature
70/100 penetration-grade 25°C
MC 3000 10°C
Cationic emulsion 10°C
Anionic emulsion 10°C
S-E1 25°C
S-E2 25°C
S-R1 25°C
S-R2 25°C
SC-E1 10°C
SC-E2 10°C
S-E1 cut back with 4.5% MC30 23°C
S-E1 cut back with 9.0% MC30 21°C
Any special formulated binder not As specified in the Contract
defined above Documentation
Conventional slurry shall not be applied at an air temperature of less than 7°C when temperatures are rising or less than 13°C when temperatures are
dropping.
During hot weather slurry operations shall be suspended when aggregate is being displaced by the spreader box or squeegees.
Rapid setting slurry or microsurfacing shall be sufficiently versatile to be laid in air temperatures of 4°C to 40°C as well as capable of being laid under damp
conditions. When the breaking process accelerates to such an extent that it renders the product unworkable to attain the required end result, no further
work shall be done until adjustments to the composition of the product have been proven through trial sections and approval by the Engineer.
A10.1.3.3 Areas inaccessible to mechanical equipment

a) Bituminous binder application
Each area that is to be sealed shall be screened off by means of fibre-reinforced paper, so that only the area to which the binder is to be applied will be
exposed.
Bituminous binders shall be applied at the rate specified in the Contract Documentation by means of a binder distributor. Hand-spray or light appropriate
equipment may be used only with the written approval of the Engineer and then only in accordance with approved methods under the strict supervision
of experienced personnel and with equipment suitable for performing the work in accordance with specified requirements.
The application of binders shall be controlled to ensure that the specified application rates are obtained.
b) Aggregate
The aggregate shall be of the same size as the aggregate in the existing surrounding seal and shall be spread by hand.
c) Rolling and brooming
Each layer of the seal shall be rolled with the most effective rollers that can be used in the area in question and thereafter the excess aggregate shall be
swept off the surface with hand brooms
d) Grit or slurry application
The Engineer may require Grit or a texture slurry to be applied to areas subjected to traffic turning actions. The slurry and application thereof shall comply
with the requirements of Section A8.3 of Chapter 8. Grit shall conform to specifications in Clause A10.1.5.14. The Engineer may order precoating of the
Grit and application of diluted cationic emulsion before spreading the Grit.
A10.1.3.4 Protection of kerbs, channels, etc.

Kerbs, channels, manholes, guard rails, bridge railings and any other structures, adjoining seals to be constructed, shall be protected from soiling. The
Contractor shall replace at his own cost any items that have been soiled.
A10.1.3.5 Moisture content

No seal shall be placed immediately after a rainy spell on an existing partly cracked and /or highly permeable surfacing resulting in the trapping of moisture
in the pavement structure. A minimum delay of 24 hours shall apply.
Seal work shall not be permitted on new granular base layers of type G1, G2 or G3 if the moisture content in the upper 50 mm exceeds 50 % of the optimum
moisture content as determined in accordance with SANS 3001 No GR30.
Seal work shall not be permitted on new granular base layers of type G4 or G5, if the moisture content in the upper 50 mm exceeds 60 % of the optimum
moisture content as determined in accordance with SANS 3001 No GR30.
These limitations shall apply even if the layer has been previously primed.

A10.1.3.6 Pretreatment
New base layers shall be pre-treated if the volumetric macro texture depth varies with more than 40 % or if the macro texture exceeds the guideline values
for different seal types as published in SABITA Manual 40.
Existing roads that require resealing shall, if so specified in the Contract Documentation, be given a pretreatment in accordance with one or more of the
methods described in Chapter 8.
The following curing periods shall apply to the various treatments listed, prior to applying to seal/reseal unless otherwise specified in Contract
Documentation:
Texture treatment using fine slurries.................................................................................................................................... 6 weeks
Coarse slurry, rapid setting slurry or microsurfacing applied as screed or rut filling ........................................................... 12 weeks
Crack sealing ....................................................................................................................................................................... 2 weeks
Asphalt patches for pavement repair ................................................................................................................................... 6 weeks
Bitumen treated granular materials..................... ................................................................................................................. 4 weeks
Untreated granular and cement stabilised materials ............................................................................................................ 2 weeks
The Engineer may reduce the specified curing period for slurry, microsurfacing and asphalt application, based on a representative corrected ball
penetration (SANS 3001-BT10), at the expected operating road surface temperature (Refer SABITA Manual 40) of less than 2,0 mm.
A10.1.3.7 Demarcation of working area

The Contractor shall demarcate the area to be sealed by means of setting out string lines along each edge of the specified seal area. The intervals for
setting out horizontal curves shall be as agreed with the Engineer.
Before the tack coat and first application of aggregate may be applied, the centreline of the road shall be demarcated by means of a clearly visible fibre
rope, pegged down with nails driven into the existing surface or primed base at intervals of 15 m on straight sections and 3,0 m apart on curves. The
demarcating rope shall be removed prior to the application of the tack coat and aggregate on the adjacent lane.
A10.1.3.8 Dust control

Any temporary deviations and construction roads shall be kept watered and damp during all sealing operations and all dust shall be removed from
surfaces before any binder, aggregate or slurry is applied.
The supply and application of water on temporary deviations will be paid for separately as specified in Clause A1.5.7.10 of Chapter 1 but payment for
watering the haul and construction roads shall be included in the unit rates tendered for the various types of seals used.
A10.1.3.9 Spray joints

a) Transverse joints
In order to prevent overlapping at junctions of separate binder applications the previous work along the joint shall be covered with removable reinforced
paper for a sufficient distance back from the joint to ensure that the sprayer is operating at the required speed before the untreated surface is reached
and also to prevent additional binder application onto the previously treated section. The same method shall be used to ensure a neat joint at the end of
the run.
b) Longitudinal joints
Longitudinal joints shall be constructed meeting the following requirements:
• Unless specified differently in the Contract Documentation, the spraying of adjacent strips shall overlap by 200 mm i.e. 100 mm of 2/3 application
and 100 mm of 1/3 application
• The string line on the joint shall demarcate the area sprayed at full application and 2/3 application
• No turning of the end nozzles or use of fish plates shall be allowed at longitudinal joints
• Aggregate shall only be applied on the area with full triple overlap binder application
• No longitudinal joints are allowed in the wheel tracks
• All aggregate applied on the 2/3 and 1/3 binder application shall be broomed back or chipped off in a neat straight line before the adjoining spray
• All stone-loss shall be made good by the Contractor at no additional cost
A10.1.3.10 Traffic limitations

Traffic shall not be allowed:
• On a single seal or double seal prior to application of the cover spray, if designed with a cover spray
• On the first layer of aggregate of a double seal, second layer of a triple seal (split application double seal) or Cape seal (single seal with slurry)
• On non-completed longitudinal joints
Stop/go positions shall not be allowed at steep grades.
Speed restriction of maximum 60 km/h shall be enforced for at least 24 hours after opening to traffic or for such time as determined by the Engineer. The
Contractor shall not allow any construction equipment which is likely to cause damage, over the completed seal.
The road shall not be opened to traffic until sufficient adhesion has developed between the binder and aggregate, cover sprays, fog sprays and
rejuvenation sprays have lost its tackiness or in the case of slurry seals, the slurry has cured completely.
When non-fluxed binders are applied and cold temperatures are expected, the road shall only be opened to traffic when the surface temperature increases
above 20oC.
During the specified embargo period, and unless MC3000 has been used, the road shall only be opened to traffic when the road surface temperature
increases above 20°C. Closures are required for the first three days after sealing when the road surface temperature falls below 20°C
When rain is imminent, the road shall only be opened to traffic once the surface is dry.
The Contractor shall erect and maintain the necessary temporary traffic-control signs in accordance with the requirements in the Contract Documentation
and the latest version of the South African Road Traffic Signs Manual.
Where a double application of slurry has been specified in case of single seals with slurry, the Contractor shall open the road to traffic before the second
layer of slurry is applied.
Where road widths allow, traffic shall be directed through placement of delineators to compact the full width of the applied seal.

Before the Contractor commences with the construction of any seal work he shall demonstrate that the equipment and processes he proposes to use will
enable him to construct the seal in accordance with the specified requirements.
At the commencement of the surfacing operation, a 200 m lane section shall be considered as a trial. After completion of each phase of the seal on this
200 m section, the Engineer will review and then approve/reject the work method. If approval is granted for a specific operation i.e. application of tack
coat, aggregate, fog or slurry, the Contractor shall proceed with that approved operation and document the approved method statement, which shall
include aggregate spread rates, the timing, type, sequence and number of roller passes, as well as the approved strategy for opening to traffic.
Trial sections for sand seals and Grit seals, using emulsion, shall specifically be designed to evaluate the appropriate timing of aggregate application to
prevent wave forming as well as the sequence and timing of rollers to prevent pick up.
Should the Contractor at any stage fail to deliver an accepted product, as adjusted, he shall rectify the problems at his own cost, demonstrate with a
further trial section that he can carry out the operation successfully and revise the method statement. No specific payment shall be made for conducting
these additional trials.
A10.1.3.13 Maintenance
The Contractor shall maintain the bituminous surface until the work is finally accepted by the Employer, after the specified Defects Notification Period.
Any damage related to design, materials and workmanship or any defects which may develop before the issue of the Performance Certificate, fair wear
and tear and 3rd party mechanical damage excepted, shall be corrected by the Contractor at his own cost.
Treatment of defects shall be carried out in accordance with Chapter 8.
Penalties in accordance with Part D of this Chapter shall apply, when applicable.
A10.1.3.14 Nominal rates of application for tender purposes

The nominal rates of application provided in these specifications are for tendering purposes only and will not necessarily be used in construction.
Application rates for all bituminous binders shall be specified at spraying temperature.
All binders, aggregates and slurry used in the various types of seals shall be applied at the rates of application as approved by the Engineer after:
• Measurement of the existing surface characteristics
• Testing of the materials proposed for use
• Aggregate spread rate determination on site
• Construction and evaluation of a trial section
• Documentation of the method statement and approval thereof
a) Single seals
The nominal rates of application given in Table A10.1.3-2 shall be used for tendering purposes only.
The actual application rate shall be as approved by the Engineer after assessing the Contractor’s design proposals.
Table A10.1.3-2: Nominal binder application rates for single seals
Nominal rates of binder application for tack coat (l/m²) Nominal aggregate spread rate (m² per m³)
Nominal size Conventional Homogeneous Hot applied Hot applied non- Aggregate spread rate for Aggregate
of aggregate bitumen and modified homogeneous homogeneous conventional and spread rate
mm emulsion. emulsion. modified modified binders homogeneous modified for non-
(Residual (Residual cold bitumen at spray at spray binders homogeneous
cold binder) temperature. temperature modified binders
bitumen)
20 1,6 1,6 1,9 2,7 70 65
14 1,4 1,4 1,7 2,1 100 90
10 1,0 1,0 1,2 1,6 140 130

7,1 0,75 0,75 0,9 1,1 200
5 0,6 0,6 0,7 250
b) Multiple stone seals

The nominal rates of application given in Tables A10.1.3-3 and A10.1.3-4 shall be for the purposes of tendering only and the actual rates of application
shall be approved by the Engineer.
The use of cut-back bitumen in the tack coat will only be permitted under special circumstances and if so specified in the Contract Documentation.
Table A10.1.3-3: Nominal rates of first application of binder and aggregate for multiple stone seals
Nominal rates of binder application for tack coat (l/m²) Nominal aggregate spread rate (m² per m³)
Nominal Conventional Homogeneous Hot applied Hot applied non- Aggregate spread rate for Aggregate
size of bitumen and modified homogeneous homogeneous conventional and spread rate
aggregate emulsion. emulsion. modified modified binders homogeneous modified for non-
mm (Residual (Residual cold bitumen at spray at spray binders homogeneous
cold binder) temperature temperature modified binders
bitumen)
20 1,2 1,2 1,3 2,0 75 65
14 0,9 0,9 1,0 1,8 110 90
10 0,7 0,7 0,8 NA 150 130
Table A10.1.3-4: Nominal rates of application for second binder and final aggregate
Nominal rates of binder application for penetration coat (l/m²) Nominal aggregate spread rate (m² per m³)
Nominal Conventional Homogeneous Hot applied Hot applied non- Aggregate spread rate for Aggregate
size of bitumen and modified homogeneous homogeneous conventional and spread rate
aggregate emulsion. emulsion. modified modified binders homogeneous modified for non-
mm (Residual (Residual cold bitumen at spray at spray binders homogeneous
cold binder) temperature temperature modified binders
bitumen)
10 1,0 1,0 1,2 1,8 165 140
7,1 0,8 0,8 - 170
7,1 (1st n/a n/a - 250
layer)*
7,1 1,1
1 1 - 150
(2nd
layer)*
5 0,6 0,6 0,9 - 230
*Split application 20/7 double seal
Residual cold binder is defined as the net binder (bitumen, polymers and additives) cold at a temperature of 20°C. The hot applied binder is calculated
by multiplying the residual cold bitumen by the “Cold to hot” conversion factors published in TRH3.
c) Nominal binder application and aggregate spread rates for sand and grit seals
The nominal rates of application given in Table A10.1.3-5 shall be for the purposes of tendering only and the actual rates of application shall be as
Table A10.1.3-5: Nominal binder and aggregate application rates for sand and Grit seals
Hot applied 70/100 Hot applied Hot applied Aggregate

Seal Type Pen bitumen at MC3000 at spray Emulsion at spray spread rate (m²
spray temperature. temperature. temperature. per m³)
Grit precoated 1,1 1,1 200
Grit unprecoated 1,2 1,3 200
Sand 1,0 1,2 1,3 180
d) Nominal binder application and aggregate spread rates for Cape seals (Single seal component)
The nominal rates of binder and aggregate application provided in Table A10.1.3-6 shall apply for tender purposes only.

Table A10.1.3-6: Nominal application for binder and single sized aggregate application in Cape seals
Conventional bitumen Homogeneous modified Hot applied Aggregate spread rate
Nominal size of
and emulsion. emulsion. homogeneous for conventional and
aggregate (mm)
modified bitumen at homogeneous
(Residual cold bitumen) (Residual cold binder) spray temperature. modified binders
20 1,2 1,2 1,5 75
14 0,9 0,9 1,2 110
10 0,65 0,65 0,8 150
Residual cold binder is defined as the net binder (bitumen, polymers and additives) cold at a temperature of 20°C. The hot applied binder is calculated
by multiplying the residual cold binder by the “Cold to hot” conversion factors published in TRH3.
e) Nominal binder application and aggregate spread rates for Cape seals (Slurry component)
The following proportions per cubic metre of slurry shall apply for tendering purposes only:
(i) First or only slurry application
Slurry aggregate (saturated volume) .............................................................................................................................. 1,0 m³
Stable-grade emulsion at mixing temperature ................................................................................................................ 230 l
Cement .......................................................................................................................................................................... 16,5kg³
Water............................................................................................................................................................................. 210 l
(ii) Second slurry application
Cement .......................................................................................................................................................................... 16,5kg³
Water............................................................................................................................................................................. 200 l
The following spread rate of slurry (saturated aggregate volume) shall apply for tender purposes only:
Table A10.1.3-7: Nominal spread rate of slurry for Cape seals
Nominal size of aggregate First layer of slurry Second layer of slurry
(mm) (m² per m³) (m² per m³)
20 140 185
14 150
1 180
f) Nominal binder application spread rates for Slurry-bound Macadams

The nominal rates of aggregate and slurry application provided in Table A10.1.3-8 shall apply for tender purposes only
Table A10.1.3-8: Nominal application rates of aggregate and Slurry for Slurry-bound Macadam
Nominal size of aggregate Aggregate spread rate
Layer Thickness (mm) Slurry Spread rate (m2/m3)
(mm) rate (m2/m³)
25 14 40 16
30 14 33 13
30 20
40 20 25 10
50 20
50 28 20 10
The following proportions per cubic metre of slurry shall apply for tendering purposes only:
Cement.......................................................................................................................................................................... 0,01m³
Water............................................................................................................................................................................. 200 l

g) Cover sprays
The nominal hot application rate of a diluted emulsion cover spray (50/50) as specified, shall for tender purposes be 0,8 l/m2.
h) Slurry
The nominal rate for a void filling coat of diluted 60 % anionic stable-grade emulsion (50/50), before application of the slurry, for tender purposes, shall be
0,8 l/m2.
The nominal binder content of the slurry (60 % anionic stable-grade emulsion), for tender purposes shall be taken as 235
l/m3. The nominal active filler content of the slurry, for tender purposes shall be taken as 16,5 kg/m3.
The nominal rate of slurry application is dependent on the thickness and shall be specified in the Contract Documentation.
i) Microsurfacing
The nominal binder content (emulsion) for tender purposes shall be taken as 180 l/m3.
The nominal rate of microsurfacing application is dependent on the thickness and shall be as specified in the Contract Documentation.
A10.1.3.16 Precoating fluid

For tender purposes the nominal quantity of precoating fluid for the relevant nominal aggregate sizes is specified in Table A10.1.3-9.
The nominal application rates as provided in Table A10.1.3-9 are for tender purposes only and must be verified in the site laboratory, with upward
adjustment in case of precoating on stockpile by hand or front-end loader.
Table A10.1.3-9: Nominal rates for precoating fluid
Nominal precoating application Nominal precoating application
Nominal aggregate size (mm) on stockpile or by hand plant precoating
rate (l/m³) rate (l/m³)
20 12 10
14 14 12
10 16 14
7,1 18 16
5 or Grit 20 18
If required, an adhesion agent approved by the Engineer shall be added to the precoating fluid at a rate of 0,5 % of the volume of precoating fluid.

A10.1.4.1 SCOPE
This Section covers the requirements of surface treatments when the selection and design of the surfacing seal is executed by the Contractor in
accordance with the Contract Documentation or when the Contractor’s alternative is accepted.
A10.1.4.2 Performance period

A performance period of two years after issuing of the Taking-over certificate, or any other period as specified in the Contract Documentation, shall apply.
A10.1.4.3 Contractor’s obligation before tendering

a) Condition assessment
Condition assessments of the road shall be carried out by the Engineer or Employer prior to tendering and the following information supplied to tenderers:
• Visual defect assessment according to TMH9 (Part A and B) per 100 m lane section
• Rutting according to TMH13 in each wheel track (Average per 10 m)
• Macro texture in wheel tracks according to TMH13 (Average per 10 m)
• Macro texture in-between wheel tracks according to TMH13 (Average per 10 m)
• Position, size and condition of existing patches
In addition to the condition assessment, the Contractor / Tenderer should also be obliged to recognise:
• Traffic loading and volumes
• Climatic conditions
• Up- and downgrades along the road
• Traffic accommodation requirements
all of which would impact on his design and construction activities.

b) Achievable specifications
When, in the opinion of the Contractor, the properties of the proposed materials do not adhere to the specifications set in this chapter and/or the prescribed
performance over the specified period cannot be met, a set of achievable specifications shall be submitted as part of the tender or, if an alternative is
proposed, to the Engineer for evaluation.
A10.1.4.4 General Specifications

a) Quality and Workmanship
Specifications regarding workmanship as defined in the relevant clauses in Part A of this Chapter, for each specific seal type, shall apply.
Prior to commencing with construction, the Contractor shall submit to the Engineer a Quality Management Plan detailing the tests and processes that will
be followed during construction of the surfacing seal.
b) Material properties
(i) Aggregate
Aggregate properties shall be in accordance with the specifications for each individual seal type as stated in the relevant section of this
chapter.
(ii) Binder
Binder properties shall be in accordance with the specifications for each individual seal type as stated in the relevant section of this chapter.
Should a proprietary product be used, the relevant properties of the selected product, not meeting the generic specifications shall be stated
as well as the achievable specifications.
c) Performance Specifications
Performance specifications are provided in D10.1.
d) Remedial work
Requirements for remedial work are provided in D10.1.10.
A10.1.5 MATERIALS
A10.1.5.1 Conventional Bituminous Binders for seal work
Unless Performance Grade binder specifications SANS 4001 BT – 10 are specified in the Contract Documentation, conventional bituminous binders shall
comply with the following specifications:
• Penetration-grade bitumen complying with SANS 4001-BT1
• Cut-back bitumen complying with SANS 4001 – BT2:
• Anionic bitumen emulsion complying with SANS 4001 – BT3
• Cationic bitumen emulsion complying with SANS 4001 – BT4
A10.1.5.2 Polymer Modified Bituminous Binders for seal work

a) Non-homogeneous (heterogeneous) modified binders (summer grade)
The bitumen-rubber binder shall comply with the requirements as set out in the latest publication of TG1.:
The Contractor shall provide the Engineer with time versus temperature relationships in regard to the above properties of his specific product before work
may start, in order to determine the final process and the acceptance limits.
If a supplier uses a diluent, an ageing test shall be required in which the binder is placed in an oven for 5 hours at 150°C, after which time it shall comply
with the above specifications.
The Contractor shall provide the performance record for three recent projects of the materials he intends to use in order to prove the successful use of
the materials. The Information shall include mean values obtained for the prescribed tests as well as any relevant comments. This information shall be
submitted at design stage.
b) Non-homogeneous modified binders (winter grade)
If non-homogenous modified binders (winter grade) are required, they shall comply with the requirements in the Contract Documentation.
c) Homogeneous cold applied modified binders
(i) Base Bitumen

The cationic emulsion shall be manufactured from bitumen complying with the requirements of SANS 4001-BT1:2012.
(ii) Polymer
The Contractor shall indicate, in the relative pay item in the Pricing Schedule, the type of polymer to be used in the blend.
(iii) Polymer modified emulsion blend
All blending shall be done at the factory. The modified binder for this project shall be specified in the Contract Documentation be as one
of binder Class SC-E1 or SC-E2, with the range of binder content and with a “(t)” added to indicate if no fluxing agent or volatile solvent is
allowed in the binder) and shall comply with the requirements of the latest publication of TG1.

The recovery binder residue shall be obtained using either the rotary vacuum evaporation or simple evaporation method. If there is any
discrepancy in the test results, then the results on recovered binder obtained from the rotary vacuum evaporation method shall be binding.
The use of a volatile solvent flux added to the bitumen shall not be permitted unless approved by the Engineer.
d) Homogeneous hot-applied modified binders (summer grades)
(i) Base Bitumen

The base bitumen or blends thereof, shall comply with the requirements of SANS 4001-BT1 or, if specified in the Contract Documentation,
with the PG binder specifications as prescribed in Chapter 9. In addition, the chemical composition of the bitumen shall be such as to
permit blending with the proposed polymer to form a stable product.
(ii) Polymer
The type and percentage of polymer to be blended with the bitumen is not prescribed, however the Contractor shall indicate, in the relevant
pay item in the Pricing Schedule, the type of polymer to be utilised.
(iii) Polymer modified blend
The polymer modified bitumen shall be blended at the factory.
The polymer modified bitumen to be used on this project shall conform to a binder Class S-E1 or S-E2 and shall comply with the
requirements of the latest publication of TG1.
The binder for the day’s production shall be tested on site to determine the softening point before any seal work is commenced with. As
a control, a hand-held spindle viscometer shall be used to monitor the viscosity of the binder at the spray temperature.
No claim for delays due to this requirement shall be considered.
e) Homogeneous hot-applied modified binders (winter grade)
The cutting back of the S-E1 binder shall only be allowed when specified in the Contract Documentation.
The percentage of cut back using MC30 shall be 4,5 % during the start and end of winter, with a maximum of 9 % during the coldest periods in the middle
of winter.
A10.1.5.3 Bituminous binders for cover sprays

Undiluted or diluted cationic spray grade emulsion shall be used as cover sprays on single or multiple stone seals in accordance with the Contract
Documentation.
Unless specified differently in the Contract Documentation, diluted cationic spray grade or anionic stable-grade emulsion (50/50) shall be used as cover
sprays on Cape seals (single plus slurry seals).
A10.1.5.4 Bituminous binders for slurry seals

The following shall be used:
• Cover spray, if specified in the Contract Documentation, using diluted 60 % anionic stable-grade emulsion (50/50) in accordance with Clause A8.2.3.2
of Chapter 8.
• Slurry seal: 60 % anionic stable-grade emulsion.
A10.1.5.5 Bituminous binders for microsurfacing overlays

The binder shall be a quickset cationic bitumen emulsion, modified with an elastomer and conforming to AC-E2 specifications as given in the latest publication of
TG1. The emulsion must be specially formulated to allow for a time of between 90 and 240 seconds when mixed with the selected aggregate, to ensure
sufficient setting time of the mix during placing.
A10.1.5.6 Water for diluting emulsions

Water used for the dilution of emulsions on site shall be suitable potable water, and each source of water used shall be tested for compatibility with the
emulsion before it is added to the bulk emulsion.
A10.1.5.7 Precoating fluid

Precoating fluid shall be manufactured from petroleum-based products. The use of tar based precoating fluids shall not be permitted.
If required, an adhesion agent approved by the Engineer shall be added to the precoating fluid at a rate of 0,5 % of the volume of precoating fluid.
A10.1.5.8 Cutting back of bitumen in a dedicated plant

The cutting back of bitumen shall only be allowed when specified in the Contract Documentation. The cutting back of bitumen shall be done with MC30
in accordance with SABITA: Guide for the control of HSE hazards associated with the field production of medium curing cutback bitumen.MC30 shall
comply with the requirements of SANS 4001 – BT2.
The temperature of the bitumen, when the MC30 is introduced shall not be higher than 140°C.
A10.1.5.9 Heating and storing of bituminous binders

a) Conventional binders
The allowed temperature ranges between which bituminous binders are stored or heated for application shall be as given in SANS 4001_BT1
Binders stored in a heated condition shall be kept in a container with a securely fitting lid and the circulatory system of which is functioning properly. The

container shall be provided with a built-in thermometer.
Binders which have been heated above the maximum allowed temperatures shall not be used and shall be removed from the site. Every effort shall be
made to maintain the binder temperature for spraying to within 5°C of the recommended temperature.
For seals the temperature limits for 70/100 penetration grade bitumen, cut back with the indicated amounts of MC-30 in parts per 100 parts of bitumen
by volume as described in Clause A10.1.5.9, shall be as set out in Table A10.1.5-1 to prevent degradation of the bitumen.
Table A10.1.5-1: Temperature/time limits for conventional binders cut back to specific proportions
Quantity of MC-30 added Temperature limits
(parts per 100 parts of Lower limit Upper limit
bitumen by volume) °C °C
0 150 175
6 146 163
11 138 154
17 132 149
22 125 143
b) Non-homogeneous (heterogenous) modified binders (summer grade)

After completion of the bitumen-rubber reaction, the handling of the binder shall be in accordance with the latest published TG1.
c) Non-homogeneous modified binders (winter grade)
The Contractor shall comply with the requirements specified in the Contract Documentation with regard to the storage, heating and spraying temperatures.
d) Homogeneous cold applied modified binders
Modified bitumen emulsions may be stored at ambient temperature for long periods, provided that some circulation/mixing takes place from time to time.
The spraying temperatures of these emulsions are the same as for conventional bitumen emulsions.
The requirements for short term handling, storage and application of these binders shall be in accordance with the latest published TG1.
e) Homogeneous hot-applied modified binders (summer grade)
Excessive temperature over extended periods will degrade all modified bitumen and negatively affect the enhanced properties of these binders.
The temperature limits for the storage and spraying of modified hot-applied binders shall be in accordance with the latest published TG1
Modified binders stored in a heated condition shall be kept in a container having a properly functioning circulation system and a securely fitting lid.
f) Homogeneous hot-applied modified binders (winter grade)
When S-E1 is cut back with MC30, the supplier shall provide temperature-viscosity relationships for the different percentages of MC30 addition and
recommendations regarding spray temperatures.
g) Bituminous binders for Cape seals
The type of bituminous binder for the tack coat shall be specified in the Contract Documentation and shall conform to the specifications in Clause
A10.1.5.1. No volatile solvents are allowed in the tack coat binder.
Cover spray for Cape seals (single seal plus slurry) shall conform to the specifications in Clause A10.1.5.1.
A10.1.5.10 Single sized aggregate

The aggregate for single, multiple and the first layer of Cape seals shall consist of approved crushed stone of the specified grade and size and shall comply
with the following requirements in regard to grading, hardness and shape and durability.
a) Grading
The grade or grades of aggregate to be used must be specified in the Contract Documentation. Table A10.1.5-2 serves as a broad guideline for selection
of the aggregate grade appropriate for the expected traffic volume.
Table A10.1.5-2: Aggregate grade
Traffic (AADT) Less than 300 300 - 3000 More than 3000
Relevant Aggregate Grade C B A

The grading shall comply with the requirements set out in Table A10.1.5-3 for grades A, B or C.
Table A10.1.5-3: Single-sized crushed aggregate grades A, B and C
Percentage by mass passing
Sieve size Nominal size (mm)
Grade
(mm)
20 14 10 7 5
37.5
28 100
20 85 - 100 100
14 0 – 35* 85 - 100 100
10 A&B 0 – 5** 0 – 35* 85 - 100 100
7,1 0 – 5** 0 – 35* 85 - 100 100
5 0 – 5** 0 – 35* 85- 100
3.35 0 – 35*
2.0 0 – 5** 0 – 5**
Grading shall comply with the requirements for grades 1 and 2 with the
C following exceptions:
* 0 − 50, ∗∗ 0 − 10,
Fines A 0.5 0.5 0.5 0.5 1.0
content
passing B 1.5 1.5 1.5 1.5 2.5
0,425 mm
sieve C 2.0 2.0 2.0 3.0 3.5
Dust A 0.2 0.2 0.2 0.5 0.5
content:
Material B 0.5 0.5 0.5 1.0 1.0
passing at
0,075 mm C 1.5 1.5 1.5 1.5 1.5
sieve (max)
Note: When determined on aggregate before treatment e.g. precoating
b) Hardness
When tested in accordance with SANS 3001 No AG10, the 10 % FACT value shall comply with the requirements in Table A10.1.5-4.
Table A10.1.5-4: Hardness
Dry 10 % FACT [kN] (min) 130 180 210
Wet 10 % FACT [kN] (min) 100 135 160
c) Polishing stone value

Unless specified differently in the Contract Documentation, the polishing stone value, measured according to SANS 3001-AG11 shall comply with the
Table A10.1.5-5: Polishing stone value
Aggregate position in seal
Exposed aggregate 48 49 50
Underlying aggregate 45 47 48
Underlying aggregate refers to the first aggregate layer of a double seal.

d) Shape
The maximum flakiness index, when tested in accordance with SANS 3001- AG4, shall comply with the requirements in Table A10.1.5-6.
Table A10.1.5-6: Flakiness
20 mm nominal size 30 30 25
7,1 mm nominal size 35 35 30

Ninety-five (95 %) percent of the particles shall have at least three fractured faces. The Average Least Dimension (ALD) of the relevant nominal aggregate
sizes, measured according to SANS-AG2 and 3, shall comply with the requirements of Table A10.1.5-7.
Table A10.1.5-7: Average least dimension

Nominal Aggregate Size (mm)
20 10,8 12 12
14 7,4 8 8
10 single 5 5,5 5,5

10 second layer NA 5 5
e) Durability
Grade A aggregate used in seals shall show a durability index of less than 4 as determined by the test method specified in Section A20.1 of Chapter 20.
Should the durability index be higher, additional testing according to current best practice shall be conducted and the results submitted to the Engineer
for evaluation.
A10.1.5.11 Aggregate for blinding single seals

The aggregate used for blinding a single seal shall consist of crushed aggregate or river sand complying with Table A10.1.5-9.
The aggregate shall be clean, hard and free from clay, silt or other deleterious matter.
A.10.1.5.12 Aggregate for Sand and Grit seals

The grading for sand and Grit seals shall comply with the requirements set out in Tables A10.1.5-8 and A10.1.5-9.
Table A10.1.5-8: Sand
7,1 100
0,300 0 - 15
0,150 0-2
Sand Equivalent
35
[%] (min)
Plasticity Index: Non-Plastic
Table A10.1.5-9: Grit

5 100
2 0 - 100
1 0 - 50
0,600 0 - 20
0,300 0 - 10
0,150 0-5
0,075 0-2
Sand Equivalent 35
[%] (min)
A10.1.5.13 Aggregate for Graded Aggregate seals

The grading and material property requirements for Graded aggregate seals shall comply with the requirements set out in the Contract Documentation.
A.10.1.5.14 Precoating of Hydrophilic aggregates

Where hydrophilic or other aggregates which may cause problems are encountered, the stone chips shall be precoated, as described below.
a) General
No precoating shall be applied where conventional and modified emulsion binders are used unless specified in the Contract Documentation.
b) Plant precoating
Where plant precoating is specified, the requirements for the end product and environmental specifications shall be in accordance with the Contract

Documentation. Adjustments to the nominal quantity of precoating fluid as indicated in Table A10.1.3-9 might be required to ensure that the final product
is uniformly coated.
c) Precoating of aggregate stockpiles
The untreated stockpile of aggregate shall be thoroughly sprayed with water, which shall be allowed to drain off. The damp aggregate shall then be loaded
into the bucket of a front-end loader with known capacity and a nominal quantity of an approved precoatlng fluid shall be sprayed evenly over the aggregate
by means of a watering can.
The mixture of aggregate and precoating fluid shall then be dumped on a site prepared as specified in Clause A10.1.5.17. This process shall be repeated
until a stockpile of approximately 15 m³ to 20 m³ has been built up.
This stockpile shall then be turned over with the front-end loader until the aggregate is uniformly coated with the precoating fluid. Three complete turnings
of the stockpile will probably be required Adjustments to the nominal quantity of precoating fluid as indicated in Table A10.1.3-9 might be required to
ensure that the final product is uniformly coated.
The time between the precoating and the placing of the aggregate shall not exceed two weeks.
A10.1.5.15 Aggregate management

a) Stockpiles
The Contractor shall heed the environmental requirements of Section A1.2 of Chapter 1, as well as the Contract Documentation, in the preparation,
operation and closure of stockpile sites. The positions for stockpiling of aggregate and the proposed operation methods shall be approved by the Engineer
before delivery of the aggregate can commence.
Sites for the stockpiling of aggregates shall be located, prepared and maintained in such a manner that:
No grass, mud, dirt or other deleterious material will be included when the aggregates are loaded for use.
They are not exposed to excessive contamination with dust arising from traffic on the road or access roads. Where necessary, temporary deviations and
access roads in the immediate proximity shall be watered or sealed
No dirt is conveyed by vehicle wheels onto the areas to be sealed or resealed whilst aggregate is being transported to or from the stockpiles.
Stockpiles shall always be covered with tarpaulins or similar protective coverings
Aggregates contaminated to the extent that it contains more than the allowable percentage of material passing through the 0.425mm sieve and 0.075mm
sieve shall not be used for sealing.
b) Removal of excess aggregate
After application of the seal all loose stones swept off the road surface are to be heaped either in the drain or gravel shoulder, whichever is applicable,
and removed in one operation. Under no circumstances shall the excess stone be swept over embankments. No sweepings are to be left on site for more
than 24 hours.
A10.1.5.16 Geosynthetic membranes for seal work

The geosynthetic shall be a non-woven geofabric, double needle punched with with properties as specified in Table A10.1.5-10.
Table A10.1.5-10: Specifications for geosynthetic membranes
Property Unit Requirement Test Method
Nominal mass g/m2 130 SANS 9864/ISO 9864

Thickness mm 1,2 SANS 9863/ISO 9863
Tensile strength (min) kN/m 7 SANS 1525/ISO 10319
Elongation at break % 40 - 60 SANS 1525/ISO 10319
Penetration load (CBR) kN 1.5 SANS 12236/ISO 12236
Puncture resistance (DART) mm 30 SANS 13433/ISO 13433
Tear strength (Min) N 215 ASTM D4533
Grab strength (Min) N 400 ASTM D4632
Melting point oC >165 ASTM D276
Bitumen retention l/m2 >1,0 ASTM D6140
A10.1.5.17 Aggregate and fillers for slurry seals

a) Aggregate
The aggregate for slurry seals shall be an approved crusher sand obtained from a parent rock having a 10 % FACT value (dry) of at least 150 or a mixture
of such crusher sand and an approved clean natural sand, where the mixture does not contain more than 25 % of natural sand. The aggregate shall be
clean, tough, durable, and angular in shape and shall comply with the grading requirements given in Table A10.1.5-11 for the slurry and the grade or type
of aggregate specified.
Aggregate for the particular application shall be specified in the Contract Documentation.

Table A10.1.5-11: Grading limits of aggregate for slurry seals
Percentage passing sieve, by mass
Sieve
size Fine slurry Coarse slurry
(mm) Fine Medium Coarse
Type 1 Type 2
Grade grade grade
14 100
10 100 85 – 100
7,1 100 100 85 – 100 70 – 90
5 100 82 - 100 70 – 90 70 – 90 60 – 80
2 90 - 100 56 – 95 45 – 70 45 – 70 40 – 60
1 65 - 95 37 – 75 28 – 50 25 – 45 25 – 45
0.600 42 - 72 22 – 50 19 – 34 15 – 30 15 – 30
0.300 23 - 48 15 – 37 12 – 25 10 – 20 10 – 20
0.150 10 - 27 7 – 20 7 – 18 6 – 15 6 – 15
0.075 1 – 15 4 – 15 2–8 4 – 10 4 – 10
The sand equivalent determined in accordance with SANS 3001 - AG5, shall be at least 35.
The immersion index of briquettes made with slurry aggregate and 70/100 penetration-grade bitumen at the specified net bitumen content for the slurry
shall be not less than 75 when tested in accordance with Chapter 20.
In addition, unless otherwise specified, for rapid setting slurries the supplier shall assess the compatibility of the binder offered with aggregates from
suitable sources nearest to the site prior to tender closure.
The slurry for Cape seals shall conform to the specifications in Table A10.1.5-11 for Fine Slurry, Fine or Medium as specified for each coat in the
b) Filler for slurry
Ordinary portland cement and portland blast-furnace cement (PBFC) shall be SANS 50197 certified.
Road lime shall be SANS 824 certified (Lime for Soil Stabilisation).
Only one of the above materials shall be used throughout in order to prevent undesirable colour differences in the surface.
A10.1.5.18 Aggregate for Microsurfacing

The aggregate shall consist of a continuously graded crusher dust, conforming to the specifications in Table A10.1.5-12.
Table A10.1.5-12: Aggregate grading limits for rapid setting slurries and microsurfacings
Sieve Size Type II Type III Stockpile

(mm) Percent Passing Percent Passing Tolerance
Overlay or Rut fill (up to 12 mm) Rut fill (more than 12 mm)
10 100 100
7,1 100 85 - 100 5%
5 90 - 100 70 - 90 5%
2 65 - 90 45 - 70 5%
1 45 - 70 28 - 50 5%
0.6 30 - 50 19 - 34 5%
0.3 18 - 30 12 - 25 4%
0.15 10 - 21 7 - 18 3%
0.075 5 - 15 5 - 15 2%

The following equipment shall be available and in good working order:
A10.1.6.1 Binder distributor

The binder distributor used for distributing the bituminous binders shall-
• Comply with SANS 3001-BT20 and shall be covered by a valid certificate of compliance with SANS 3001-BT20, not older than 12 months,

issued by an accredited testing organisation
• Not have any fuel, oil or binder leaks;
• Have a straight and clean spraybar, all the spray heads of which shall be of the same type which open simultaneously and shall not leak when
closed;
• Have its spray heads all spraying at the same angle to the spraybar and the height adjusted to the correct level so as to obtain the required
overlapping. The uneven application of binder shall be unacceptable.
• Have its sieve undamaged and clean;
• Be under the direct control of an operator approved by the Engineer on the grounds of a CV with experience and list of contracts completed
with references, in writing or a certificate of competence signed by a representative of a road authority;
• Be fitted with a suitable cut-off spray-head (end nozzles) or fishplates to prevent over spraying onto gravel shoulders or staining of concrete
elements on the edge of the surfacing of the road.
• Be capable of spraying the binder at the specified applications rates. The pump of the distributor shall be capable of delivering the binder at the
spray bar nozzles at the correct pressure to obtain the specified application rates, irrespective of the viscosity properties of the prescribed binder
and the number of nozzles open.
• Fitted with a suitable valve or other access gate for taking of samples of the binder for testing purposes.
The binder distributor, pumps and nozzles, used for non-homogeneous modified binder shall be adapted to spray the rubber modified binder satisfactorily.
The Contractor shall provide proof by way of a test on the site that the binder distributor has sufficient reserve power to maintain the required constant
speed up the steepest incline to which spray has to be applied and to obtain a uniform distribution of the binder.
The transverse distribution of the spray bar shall be field-verified by means of SANS 3001-BT24. Measurements of transverse distribution (‘Bucket test’)
for a binder distributor. The maximum permissible tolerance permitted between the troughs (excluding the outer 300 mm) is dependent on the viscosity
of the binder type being applied and shall be as follows:
• All emulsions, cutback and penetration grade bitumens – 5 %
• Hot homogeneous modified bitumens – 7 %
• Non-homogeneous binders (bitumen rubber) – 10 %
The spray bar shall be of such design as to allow for any adjustments to be made in order to meet the above tolerances. This procedure shall be carried
out each time the distributor is first established on site and once a week thereafter or when a problem with transverse distribution is suspected. The
distributor shall thus have a set of troughs available in order to allow the execution of the test. For limited quantities of spray-work, the Engineer may
accept the results of a recently completed distribution test that has been recorded and approved by an independent supervisor on the distributor’s test
log book.
The transverse distribution of spray flairs shall be field verified according to SANS 3001-BT24 and Clause A20.1.5.9 of Chapter 20. The maximum
permissible tolerance permitted for each trough form the average of the nine troughs is 10 %.
A10.1.6.2 Chip spreaders

The chip spreaders shall be capable of spreading stone of the specified size uniformly and shall be capable of adjustment to permit variation of the rate
of application within the specified tolerances and uniform spreading in both the transverse and longitudinal directions.
The chip spreader shall be capable of delivering a proper and uniform transverse distribution of chips across the width of application. The chip distribution
shall be tested by means of canvas patches, each 1,0 m by 1,0 m and placed side by side over the full width of application. The mass of chips spread
onto each individual canvas patch shall not deviate by more than 10 % from the spread rate determined as part of the trial section and recorded in the
approved method statement.
At least two chip spreaders shall be provided on site, one of which shall be self-propelled.
In cases where the sprayed width exceeds the maximum spread width of the chip spreader, an additional chip spreader shall be provided to apply
aggregate on the remaining strip within twenty seconds of the first chip spreader.
Spreaders which are not self-propelled shall be of a type that can be attached quickly to the rear of trucks and operated while backed over the aggregate
being spread.
A non-self-propelled chip spreader may only be used in the event:
• of a breakdown of the self-propelled chip spreader during a pull, and shall be limited to the completion of that pull. No further application of
binder shall be permitted until such time as the self-propelled chip spreader is repaired or replaced.
• of spreading Class 3 aggregate, Graded aggregate, Sand- or Grit seals and Slurry-bound Macadam seals.
A10.1.6.3 Rollers
a) General
Sufficient operational rollers of each of the following types shall be available on the works to maintain the required tempo of work.
• Pneumatic tyred rollers (minimum two)
• Rubber-soled steel wheel rollers (as and when specified in the Contract Documentation)
• Light steel wheeled rollers of 2 – 4 tons (minimum two)
• Heavy steel wheel rollers of 5 – 12 tons (as and when specified in the Contract Documentation)

The timing, sequence of rolling and number of passes for each seal type shall be in accordance with the approved method statements following completion
of the trial sections.
No seal work shall continue if the required rollers are not on site or not in an operational condition.
b) Pneumatic-tyred rollers
Pneumatic-tyred rollers shall be of a self-propelled type equipped with smooth flat profile pneumatic tyres of uniform size and diameter. The mass of the
roller shall not be less than 2 ton per wheel.
The rollers shall be equipped with suitable devices for keeping the wheels wet and clean with water or non-petroleum-based products during operation.
The wheels of the roller shall be so spaced that one pass of the roller will provide one complete coverage equal to the rolling width of the machine. The
total operating mass and tyre pressure shall be in accordance with the manufacturer’s recommendations. Individual tyre pressures shall not differ by more
than 35 kPa from one another.
In case of sealing more than 12 000 m2 per day, using hot binder, at least three pneumatic-tyred rollers are required.
c) Rubber-soled steel-wheeled rollers
Rubber-soled steel-wheeled rollers shall be self-propelled and have a mass of between 6 and 8 tons. It shall be equipped with suitable devices for cleaning
and moistening the wheels using water or non-petroleum-based products. The wheels of the roller shall be so arranged as to give one or two complete
coverage by one passage of the roller, over a width equal to the rolling width of the roller.
d) Steel-wheeled rollers
Steel-wheeled rollers shall be sell-propelled tandem rollers of between 2 and 4 tons mass and shall be equipped with suitable devices for cleaning and
moistening the wheels using water or non-petroleum-based products. Heavier rollers shall only be permitted when specified in the Contract Documentation
and tested for excessive crushing during construction of the trial section. No steel-wheeled rollers shall be used on the final aggregate layer without the
consent of the Engineer, unless a cover spray will be applied after brooming the surface.
A10.1.6.4 Water sprinkler

The water sprinkler shall have efficient spray equipment, capable of spraying a uniform film of water over the whole area to be primed.
A10.1.6.5 Rotary broom

The rotary broom shall be height adjustable self-propelled or a towed type supplied together with a suitable pneumatic-tyred towing vehicle. The minimum
bristle length allowed shall be 70 % of the initial length.
A10.1.6.6 Drag broom

A triangular or “Z-shaped” drag broom shall be provided together with a suitable pneumatic-tyred towing vehicle and capable of being ballasted to distribute
the specified seal aggregate size.
A10.1.6.7 Miscellaneous equipment

Sufficient equipment for handling and hauling aggregate, binder and slurry, and blending units for non-homogeneous modified binders, shall be provided
to ensure prompt and continuous placing and application of bituminous materials as specified. The Contractor shall have available all the necessary
ancillary equipment, which shall include hand brooms, mat or reinforced paper for joints, string, nails and hand tools to carry out the work efficiently.
Suitable protective clothing shall be worn at all times.
Suitable fire-fighting equipment for dealing with fires shall be available on site, together with suitable first aid equipment for dealing with injuries and
evacuation transport in case of bitumen burns. (Refer to Sabita Manual 8: Bitumen Safety Handbook.)
The Engineer shall be entitled to request reserve plant should there be any doubt as to the efficiency or capability of the equipment provided.
A10.1.6.8 Batch mixer for slurry

A mixer shall be provided in a good working order capable of producing a uniform slurry of the constituent materials. All the constituents of the slurry shall
be accurately proportioned and due care and attention shall be given to the sequence in which the ingredients are introduced into the mixer and to the
period of mixing. Volume batching will only be permitted with the written approval of the Engineer. Mixing shall be continued until the materials in each
batch are thoroughly blended.
A10.1.6.9 Mass-measuring device for large batch mixers

Where payment per ton is specified, the Contractor shall provide and install suitable gauged mass-measuring device on the site. The device shall be
provided with a printer for printing the mass, the time and date. The printed data shall be submitted to the Engineer on a daily basis.
A10.1.6.10 Loader for aggregate

A loader, or equivalent capacity labour force where so required in the Contract Documentation, compatible with the needs and capacity of the trucks or
mixer, in the case of slurry, unit shall be available at the stockpiling site.
A10.1.6.11 Continuous slurry machine

Aggregate and filler contained in separate bins shall be fed through metering devices at controlled rates to the mixer. Water and bitumen emulsion
contained in separate tanks shall similarly be pumped to the mixer at controlled rates through precise metering devices to enable the various constituents
to be combined continuously to the selected or prescribed formulation. The mixing of the slurry shall be at a suitable rate adjusted to ensure complete
blending of the ingredients and uniformity of mix before depositing into the spreader box.
The spreader box shall be so constructed as to distribute the weight onto metal skids in such a way that no damage shall be done to the surface when

the box is in operation.
Soft rubber belting shall be attached to the framework in such a manner as to prevent slurry from being spilt past the sides of the spreader box when the
box is in operation.
The spreader box shall be capable of spreading a uniform application of the slurry in adjustable widths from 1,5 m to 4,0 m, at specified rates, and it shall
have efficient mechanical means of adjusting the rates and widths of application specified.
The mixing and application of microsurfacing shall be done by a mixer designed to provide a rapid mixing time, and sufficient agitation within the spreading
system to prevent segregation or premature hardening. The appropriate workability measured by the flow (Consistency test: ASTM 3910) shall be verified
during the first application and recorded as part of a method statement.
A10.1.6.12 Spreader box for slurry

If the use of a spreader box has been permitted in the Contract Documentation, the type of spreader box used for spreading the slurry shall be submitted
to the Engineer, in advance, for approval. The spreader box for rapid setting slurry shall be of a proven and approved type, fitted with a proven and
approved device to ensure sufficient agitation within the spreader system.

A10.1.7.1 Single Seals
a) Preparation
All specifications as stated in Clause A10.1.3 shall be met.
b) Application of tack coat and aggregate
The actual rates of application of binder and aggregate to be used during the construction shall be determined after measurement and evaluation of the
existing surface and testing of the aggregate properties the Contractor proposes to use for the seal. The designs shall be submitted to the Engineer for
approval prior to any sealing being carried out.
Bituminous binders shall be applied by means of a binder distributor, unless otherwise approved.
If a choice can be exercised areas inaccessible to mechanical equipment shall preferably be restricted to areas that are not subjected to traffic.
A bituminous tack coat consisting of the type and grade of binder specified in these specifications or in the Contract Documentation for each type of
bituminous sea, shall be uniformly sprayed on the properly cleaned and prepared base or existing surface over the full specified width of the seal.
Where the tank of the binder distributor could become empty during spraying against inclines, the spraying shall be done while the binder distributor is
moving uphill. Should the Engineer be of the opinion that the Contractor is unable to place the sealant over the full specified width in one movement the
Contractor shall execute the spraying and the distribution of the aggregate in strips.
Immediately after the binder has been sprayed it shall be covered with clean, dry or precoated aggregate of the size specified in these specifications
under each of the appropriate sections for each type of seal. The only exception is the spread of sand or Grit after application of an emulsion. In this case
the emulsion must start to break before application of the aggregate to prevent wave forming.
The aggregate shall be applied uniformly by means of self-propelled chip spreaders, unless otherwise specified. The spreading of the chips shall be done
as closely as possible behind the distributor. The chip spreader shall be so operated that the tack coat shall be covered with aggregate before the wheels
of the chip spreader or truck pass over the uncovered lack coat
The quantity of bitumen sprayed in any single spray operation shall be governed by:
• The quantity of available aggregate. The number of trucks available shall be sufficient to ensure the continuous application of stone behind the
distributor.
• Available roller capacity at normal operating speed. In case of hot penetration grade and hot modified binder, at least one roller pass is required
within 5 minutes after application of the binder
Areas with varying or narrowing widths on which binder distributors can be used shall be screened off by means of fibre-reinforced paper, so that only the
area to which the binder is to be applied, will be exposed. The binder shall then be applied at the specified rate with a binder distributor. Immediately
thereafter the fibre-reinforced paper shall be removed, the aggregate shall be applied and the seal shall be completed.
Where hot binders are used, all the aggregate shall be applied immediately but not more than 2 minutes after the application of the tack coat.
c) Application in case of geosynthetic membrane
Following compliance with all relevant specifications in Clause A10.1.3, a tack coat of cationic 65 % bitumen emulsion (without solvents) or SC-E1(t) shall
be applied at a spray rate of 0,8l/m² by means of a hand applicator or distributor. The geosynthetic shall then be applied to the wet tack coat by hand or
a suitable mechanical applicator and rolled with a suitable roller to ensure satisfactory bonding between the geosynthetic and the road surface. All wrinkles
shall be smoothed out.
The nominal rate of the binder for the single seal shall be as specified in the Contract Documentation.
d) Initial rolling of aggregate
Immediately after the aggregate has been applied on any hot binder, rolling shall be commenced.
In the case of emulsions, immediate rolling by means of self-propelled 2-4 ton steel wheel rollers shall be only permitted if excessive crushing of aggregate
does not occur and if another layer of binder will be applied. Pneumatic-tyred rolling shall be delayed until the emulsion has been allowed to break
sufficiently to firmly secure the aggregate. Rolling shall be postponed if there is excessive pick-up of aggregate on the tyres of the pneumatic type roller.
Rollers shall operate parallel to the centre line of the road from the shoulders inwards towards the crown of the road until the entire surface has been
covered at least four times with the wheels of the roller.

The process (sequence, timing and roller passes) for each seal type shall be finalised during construction of a trial section and documented in a method
statement.
e) Broom drag and final rolling of aggregate
After the bituminous binder has set-up sufficiently to prevent any aggregate from being dislodged, and if directed by the Engineer, the surface shall be
slowly dragged with a broom drag to ensure even distribution of the aggregate. If there are areas which are deficient in stone chips, additional material
shall be added by hand to leave a single layer of chips lying shoulder to shoulder after rolling and traffic compaction.
The Contractor shall provide a back-chipping team, together with a pneumatic-tyred roller, of sufficient capacity to ensure that back-chipping and rolling
of aggregate shall be completed within thirty minutes after initial application of the aggregate.
It is essential to ensure that only one layer of aggregate is applied and every care shall be taken to avoid over-application of aggregate.
After completing the spreading of the aggregate, the surface shall be rolled with a self-propelled pneumatlc-tyred roller with a minimum load of 2,0 t per
wheel for a minimum of four coverages. Except in the case of single seals, constructed without a cover spray, final rolling after brooming off loose
aggregate, shall then be done with a steel-wheeled roller with a mass of 2-4 tons working parallel to the centre line of the road from the shoulders towards
the crown of the road, until every portion of the surface concerned has been covered by at least four passes of the roller. If excessive crushing occurs
under the rollers, such rolling shall be stopped regardless of the number of passes completed by the roller.
All aggregate contaminated by fuel, oil or grease shall be removed and replaced with clean aggregate.
The process for each seal type shall be finalised during construction of a trial section and documented in a method statement.
All loose aggregate shall be broomed off the surface with a rotary broom or hard brooms before opening to traffic.
The finished surface shall be well-knit and have a uniform appearance free of roller-lyre marks.
f) Cover spray
When required by the Contract Documentation or if so directed by the Engineer in writing, a cover spray of diluted cationic spray grade emulsion shall be
applied to the surface of the aggregate by means of a pressure distributor at the rate and dilution specified in the Contract Documentation or as directed
by the Engineer.
g) Blinding
If required in the Contract Documentation or as may be directed by the Engineer, a light blinding layer of washed natural or crusher sand, conforming to
Clause A10.1.5.11 shall be applied by the Contractor to prevent aggregate from being picked up by traffic. The blinding layer shall be spread evenly over
the full indicated surface.
A10.1.7.2 Multiple stone seals

a) Preparation
All specifications as stated in Clause A10.1.3 shall be met.
b) Application of tack coat and first layer of aggregate
The binder of the type and grade and the aggregate of the size and grade specified in the schedule of quantities and according to the design approved
by the Engineer, shall be applied as specified in Clause A10.1.7.1b).
c) Application in case of geosynthetic membrane
Following compliance with all relevant specifications in Clause A10.1.3, a tack coat of cationic 65 % bitumen emulsion (without solvents) or SC-E1(t) shall
be applied at a spray rate of 0,8l/m² by means of a hand applicator or distributor. The geosynthetic shall then be applied to the wet tack coat by hand or
a suitable mechanical applicator and rolled with a suitable roller to ensure satisfactory bonding between the geosynthetic and the road surface. All wrinkles
shall be smoothed out.
The nominal rate of the binder for the seal shall be as specified in the Contract Documentation.
d) Initial rolling
Initial rolling shall be carried out as specified in Clause A10.1.7.1d).
e) Broom drag and final rolling of aggregate
Dragging and final rolling of aggregate shall be carried out as specified in Clause A10.1.7.1e).
f) Second application of bituminous binder and aggregate
The second bituminous binder shall be applied and followed by the second layer of aggregate of the size specified, in accordance with the approved
method statement.
Where hot binders are used, all the aggregate shall be applied immediately but not more than 2 minutes after the application of the tack coat.
The second application of binder shall preferably take place within 48 hours of the application of the tack coat.
Where a 20 mm + double 7,1 mm split application seal is to be constructed, the application of the 7,1 mm aggregate shall be carried out in two separate
operations. The first application of the 7,1 mm aggregate shall be placed before application of the second binder application, at the application rate
determined during construction of the trial section and then slowly dragged with a drag broom to ensure an even distribution.
g) Initial rolling of second and final layer
Initial rolling of the second layer of aggregate, or final layer in case of the 20 mm and double 7,1 mm split application seal, shall be carried out as
specified in Clause A10.1.7.1d) or as per approved method statement

h) Broom drag and final rolling of second layer
Dragging and final rolling of the second layer of aggregate shall be carried out as specified in Clause A10.1.7.1e) or as per approved method statement.
i) Cover spray
When required by the Contract Documentation or if so directed by the Engineer in writing, a cover spray of diluted SC-E1 or diluted cationic spray grade
emulsion shall be applied to the surface of the aggregate by means of a pressure distributor at the rate and dilution specified in the Contract Documentation
or as directed by the Engineer.
A10.1.7.3 Sand and Grit seals

a) Application of sand seals or Grit seals
Application of sand and Grit seals shall be strictly in accordance with the best practice determined during the trial section and approved in the method
statement.
During the rolling process, any uneven application of sand shall be rectified with a light broom drag or other suitable apparatus.
Where an emulsion is required to be applied in two applications, the surface can be opened to controlled traffic after the first application of emulsion and
sand, as soon as it is convenient to do so. The second application of emulsion and sand may be applied when the first application has cured sufficiently
for it to take the traffic without requiring brooming back of the sand. All loose sand and deleterious material shall be removed from the surface and any
damaged or defective areas rectified before the second application of binder and sand.
While the traffic is using the road, the sand shall be continuously broomed back onto the road until the binder has cured sufficiently to retain the sand and
until traffic does not damage the surface. The sweeping-back process shall be done with a rotary broom or manually and may take as long as two months
before the surface finally settles down. Tenders shall be based on brooming back for five times.
As wet sand with high dust and or fines content could be difficult to apply, the preparation of the sand should be done well ahead of the actual construction
and the appropriate moisture content determined and tested during construction of the trial section.
Where required by the Contract Documentation, the Grit shall be precoated with an approved precoating agent.
A10.1.7.4 Graded Aggregate Seals (OTTA Seals)

a) Application of the graded aggregate seal
Requirements for the construction of graded aggregate seals shall be in accordance with the Contract Documentation.
A10.1.7.5 Slurry Seals

a) Application of slurry
Material which is not properly mixed or in which the emulsion shows signs of having broken during mixing shall not be applied to the road.
In order to achieve the required workability, the slurry consistency when measured in accordance with ASTM D3910 section 6.1 shall be within the ranges
of the target flow stated in Table A10.1.7-1 or the adjusted ranges, approved by the Engineer, after construction of the trial section.
Table A10.1.7-1: Slurry consistency requirements
Application Target Flow
Slurry bound macadam 60 mm
Hand application of slurry for texture 30 - 40 mm

treatment or Cape seals
Slurry overlay 20 - 30 mm
Micro surfacing 10 - 20 mm
A10.1.7.6 Microsurfacing
a) Application of microsurfacing
Microsurfacing shall be applied using a continuous slurry machine as specified in Clause A10.1.6.11.
The applied thickness of the microsurfacing, before compaction, should be 20-25 % more than the desired end thickness
The formulation of the product shall be such that complete curing will take place within a maximum of 4 hours, regardless of the climatic conditions during
construction, to allow opening to traffic.
Ball penetration (SANS 3001-BT10), corrected for the expected road surface temperature (refer SABITA Manual 40), on the product shall reduce to less
than 2,0 mm within a period of 4 weeks.
A10.1.7.7 Cape seals (Stone and slurry combination seals)

a) Application of tack coat and aggregate
The binder of the type and grade and the aggregate of the size and grade specified in the schedule of quantities and Contract Documentation, shall be
applied as specified for single seals in Clause A10.1.7.1. If the bituminous binder used for the tack coat is of Class S-E1/S-E2 or 70/100 penetration grade
bitumen, the large aggregate for the first layer shall be pre-coated with a bituminous based pre-coating fluid, according to Clause A10.1.5.14 at the rate
If the bituminous binder used for the tack coat is the 70 % polymer modified spray grade emulsion of Class SC-E1(t)/SC-E2(t), no pre-coating of the large

aggregate shall be required, unless specified in the Contract Documentation.
The aggregate of the single seal component shall be uniformly spread resembling the “Open Shoulder-to-shoulder” matrix (Refer TRH3) to allow the
slurry to properly penetrate into the voids between the aggregate.
b) Initial rolling
Initial rolling shall be carried out as specified in Clause A10.1.7.1d).
c) Broom drag and final rolling of aggregate
Dragging and final rolling of aggregate shall be carried out as specified in Clause A10.1.7.1e).
d) Second application of bituminous binder (cover spray)
A cover spray of diluted emulsion shall be applied to the surface of the large aggregate at the rate approved by the Engineer.
In case of emulsion being used in the tack coat, the cover spray shall only be applied after the tack coat binder has completely cured.
e) Slurry application
(i) Condition of surface

The surface shall be rolled once with a light flat-wheeled roller early in the morning on the day of sealing to depress any loose stones that
may have been displaced.
The surface shall be cleaned to remove all dust, mud, leaves, etc. and shall have a uniform closely knit appearance, with edges trimmed
correctly to the specified width.
(ii) Timing of slurry application
The slurry shall be applied only after the cover spray has completely cured or dried out
(iii) Mixing of slurry
Mixing of slurry shall in done in accordance with Clause A10.1.6.8.
(iv) Application of slurry
The method of application specified in the Contract Documentation shall be used.
The nominal rates of application given in Table A10.1.5-1 are intended for tendering purposes only and the actual rates of application on
the site shall be as per approved method statement after completion of the trial section.
Before slurry is applied, the road surface shall be thoroughly cleaned and lightly sprinkled with water but no free water shall be present
on the surface when the slurry is applied.
The slurry shall be applied in one or two layers in the case of 20 mm aggregate and in one layer in the case of 14 mm or 10 mm aggregate,
unless otherwise specified in the Contract Documentation.
Both the first and second layer of slurry shall be spread to the full final width of the primed surface.
When the slurry is applied in two layers, the first layer of slurry shall be struck off level with the tops of the stones in the aggregate layer
so that after application, the tops of the stones will be just visible.
For seals using 10 mm or 14 mm nominal sized aggregate and the final slurry layer in case of the 20 mm Cape seal, the slurry shall also
be struck off so that the tops of the stone will be just visible after the emulsion has cured.
Rolling of the slurry shall commence after the slurry has dried sufficiently. Each layer of slurry shall be roller compacted by at least three
roller passes with a pneumatic-tyred roller. However, the final layer shall be compacted until the required in situ water permeability is less
than 1.0l/h when measured by means of method SANS 3001-BT12.
The second layer shall be applied only after sufficient time has been allowed for the first layer to cure. And shall not be less than 24 hours.
The surface shall be thoroughly cleaned of all dust, dirt or foreign materials before the second layer of slurry is applied.
Unless specified differently in the Contract Documentation both slurry layers shall be spread only by hand and not with a spreader box.
The slurry shall be worked from side to side and criss-cross with the aid of squeegees so as to fill as many spaces as possible.
The slurry batch shall be discharged onto the road in small increments by means of a chute. When the slurry is applied, the squeegee
squad shall be allowed to complete the spreading of each batch discharged onto the road, using squeegees, before the next is discharged.
The Contractor shall ensure that either edge of the road surface is finished to the specified widths and lines. All stones dislodged in the
process of applying the slurry shall be removed on the same day on which the slurry seal has been applied. All spillage of slurry or excess
slurry shall be neatly removed from the road and discharged at an approved site.
The rate of application shall be measured by cubic metre of saturated aggregate, contained in the slurry applied per square metre of
surfacing.
The slurry shall be applied to the full road width in one application. If approved by the Engineer, the slurry may be applied in half-widths of
road, provided that the work is so programmed that the slurry is applied to both half-widths on two successive days in order to complete a
section of full road width in two days.

A10.1.7.8 Slurry-bound Macadam Seal
a) Application of aggregate
The aggregate of size and grade specified in the schedule of quantities and Contract Documentation shall be spread evenly to the specified thickness. It is
then levelled out with rakes, shovels, screed boards and compacted with a light pedestrian roller in static mode. The slurry is then mixed and evenly spread
over the macadam aggregate by wheelbarrow, shovels and squeegees. A pedestrian type plate vibratory compactor is then used to achieve penetration of
the slurry until all the voids within the Macadam are filled. A final slurry is then applied.
A moist burlap drag shall be drawn over the final slurry to ensure an overall and even texture. The burlap will be dragged perpendicular across the centre-
line of the road. Should breaking of the emulsion, segregation of the mix or formation of the lumps occur during the application of the slurry, the slurry
operations shall be discontinued at once and any defective material removed from the road. Successive strips of slurry shall overlap transversely by not
less than 25 mm not more than 150 mm. Any overlapping and any omitted areas shall be rectified with squeegees. The contractor shall ensure that either
edge of the slurry is finished to the prescribed widths and lines. All stones dislodged in the process of applying the slurry shall be removed from the road
and spoiled. Where slurry is spread by hand, the squeegee squad shall be allowed to complete the spreading of each batch onto the road, using squeegees,
before the next is discharged. The slurry shall then be worked from side to side criss-cross with aid of squeegees so as to fill as many voids as possible.
The finished slurry slayer shall present a smooth, dense and homogenous surface, true to level and camber on the cross fall and from tear cracks,
corrugation, rutting or any other irregularity. It shall be free from depressions or elevations and when a straight edge two meters long is laid on the treated
surface parallel or at right angles to the centre of the road, the surface shall nowhere vary from the lower edge by more than 3,0 mm along the treated area,
the outer edge of the slurry shall be formed neatly in a straight line to the widths ordered by the engineer.
In case a further surfacing layer is applied, the slurry shall be left open to the atmosphere to age and oxidize for a minimum period of 4 weeks, i.e. the slurry
shall not be overlaid with any seal or asphalt for 4 weeks
No slurry shall be laid when the ambient temperature is less than 10 o C and in any event not during rain or when free water standing on the surface.
A10.1.8 WORKMANSHIP
A10.1.8.1 General aspects related to quality and workmanship
a) Surface tolerances
Where newly constructed base or shoulder areas are to be sealed, the surfaces shall be checked for compliance with the surface tolerances and all other
requirements specified in Chapter 5. Any portions that do not meet these requirements shall first be either corrected or removed and reconstructed before
they are sealed.
Surface tolerances specified for the base shall also apply to the sealed surface.
The edges of the completed seal shall be continuously true to line with a maximum allowable deviation from the specified edge line of 15 mm.
b) General appearance
The completed seal shall be free from corrugations or any other wave effect where depressions are preceded and followed by humps or ridges.
The completed surfacing shall be of uniform texture without gaps or patches and shall be free from longitudinal and transverse corrugations and any loose
aggregate or binder spillage.
c) Repair of defects
Any areas which show signs of bleeding, aggregate loss, non-uniformity of texture and surface irregularities after the section has been opened to traffic
shall be corrected as specified in Chapter 8. Corrective work shall be carried out in such a manner as to blend in colour, texture and finish with adjacent
work.
In case of Cape seals, slurry or microsurfacing, any damage to the slurry by rain or traffic before the slurry has cured shall be rectified by the Contractor
at his own expense.
d) Aggregate spread rate and binder application
The maximum permissible variation from the rates of application of aggregate, as approved by the Engineer after verification during the trial section, shall
be plus or minus 5 %.
The maximum permissible variation in application rate from that specified (measured at spray temperature), shall be 5 % for all binders, except diluted
emulsions. In case of diluted emulsions, the variation shall be calculated in terms of the emulsion before dilution.
A lot for acceptance control purposes shall be at least 600 litres. Lots smaller than 600 litres shall be combined with succeeding lots until a combined lot
not less than 600 litres is obtained.
Provided that corrections to subsequent layers (penetration coat and/or cover sprays) could be applied in accordance with good practice, the Engineer
could conditionally accept out of tolerance variations at the reduced rates of payment listed in Table A10.1.8-1.
Variations in binder application rates in excess of those tabled shall be deemed rejected. No payment will be made for bituminous binder applied in excess
of the rate ordered plus the permitted tolerance.
Rejected sprays shall result in rejection of the total seal without any payment.
Conditional acceptance does not relieve the Contractor from his obligations related to the seal performance.

Table A10.1.8-1: Payment reduction factors for conditionally accepted binder application rates
Hot applied binder and
Diluted emulsion.
undiluted emulsion % Payment of tendered rate for
Deviation from specified
Deviation from specified rate. seal
spray rate Net emulsion. (%)
At spray temperature. (%)
±5,0 ±5,0 100,00
±6,0 ±6,0 97,56
±7,0 ±7,0 94,32
±8,0 ±8,0 90,28
±9,0 ±9,0 85,44
±10,0 ±10,0 79,80
The equation for determining the reduced payment per binder layer is provided below:
𝑃 = −0.004𝐷2 + 0.0196𝐷 + 1.002
Where
P = % Payment of the tendered rate for the seal
D = Deviation from the specified rate
In the case of single seals, where a diluted emulsion cover spray is not specified, the Engineer may permit the application of a diluted emulsion fog spray
in instances where tack coat application rates are below the minimum allowable tolerances. In such instances, no additional payment over and above the
unit rate tendered for the accepted seal, plus or minus any variation from the nominal to the rate ordered, will be made.
In the case of single seals, where a diluted emulsion cover spray is specified, no payment will be made for bituminous binder in the tack coat applied in
excess or at a rate lower than the specified rate, plus or minus the permitted tolerance unless in the opinion of the Engineer, such overspray or any
shortages can be satisfactorily corrected by the adjustment to the application rate of the cover spray, or an additional cover spray, if such correction is
effected.
In the case of multiple stone seals, no payment will be made for any bituminous binder applied in excess of, or at a rate lower, than that specified, plus or
minus the permitted tolerance. In such instances the Engineer may permit the adjustment to any subsequent spray applications to achieve the total net
binder as determined and specified for the particular seal type. In the event of under application of binder, the Engineer may similarly approve the
application, or an increased application, of an appropriate cover spray if the overall integrity/performance of the surface seal is deemed not to be
compromised.
In the latter two cases, where some of the layers are conditionally accepted, a weighted payment adjustment shall be calculated based on the payment
adjustment for the specific layer and the proportional cost of the binder layer to the total binder cost, as determined from the tendered variation for each
binder. An example is provided in Table A10.1.8-2.
Table A10.1.8-2: Calculation of weighted payment adjustment

Specified
Variation Cost of
hot Applied Adjustment Weighted %Cost of
Binder layer Binder % out Acceptance (R/l) binder
application rate factor % adjustment layer
tendered (R/l)
rate
First application
(tack coat) Hot: S-R1 2.00 2.20 10.00 79.80 Conditional 46.49 6.00 12 58.25
Second application
(penetration coat)
Hot: S-E1 1.30 1.20 7.69 91.61 Conditional 28.91 5.00 6.5 31.55
Cover spray Diluted Cat 65 1.00 1.10

% Emulsion in
dilution 70 Cold: Cat 65 0.7 0.77 10.00 79.80 Conditional 8.13 3.00 2.1 10.19
% Payment 83.53 20.60

Tendered price/m2 62.00
Payment /m2 51.79
The weighted adjusted payment factor in the case of multiple binder applications could directly be calculated using the following equation:

Where
Pw = Weighted adjusted payment factor
P1 = Payment adjustment factor for the tack coat
P2 = Payment adjustment factor for the penetration coat
P3 = Payment adjustment factor for the emulsion component of the cover spray
C1 = Cost of the tack coat,
calculated by multiplying the specified hot application rate with the tendered variation for the binder
C2 = Cost of the penetration coat,
calculated by multiplying the specified hot application rate with the tendered variation for the binder
C3 = Cost of the cover spray,
calculated by multiplying the specified application rate with the tendered variation for the emulsion
In the case of graded aggregate seals and sand seals the engineer may accept, an application of binder sprayed above the allowable tolerance subject
to the contractor, at his own cost, applying and rolling any additional sand/aggregate necessary as a result of such over application.
10-24
DRAFT STANDARD (DS) OCTOBER 2020
B10.1 GENERAL REQUIREMENTS FOR SURFACE TREATMENTS
CONTENTS
B10.1.1 SCOPE
B10.1.2 DEFINITIONS
B10.1.3 GENERAL
B10.1.5 MATERIALS
B10.1.8 WORKMANSHIP
B10.1.1 SCOPE
All the preparation activities are suitable components for labour enhancement (sweeping and watering). The stone spray application is divided into two
main activities namely the binder spray application and the stone spreading. The binder spray application is suitable only if bitumen emulsions are used,
whilst the stone spreading is reasonably suitable using walk behind chip spreaders. Rolling the stone is a reasonably suitable labour component using
pedestrian rollers.
In the interest of limiting the exposure of workers to the burns and inhalation of fumes associated with the application of penetration bitumen by hand,
only bitumen emulsions are considered for labour intensive methods for spray seal work. Only emulsion products are suitable for binder applications by
hand methods.
B10.1.2 DEFINITIONS
The provisions of PART A shall apply.
B10.1.3 GENERAL

B10.1.5 MATERIALS

B10.1.6.1 Binder Distributor: Hand Sprayer
A motorised hot bitumen emulsion hand sprayer, complying with the following requirements, shall be used:
• Engine: 5kW diesel or 3,7kW petrol engine.
• Pump: Gear type pump, direct from the output shaft of the engine reduction gear through a flexible coupling, capable of delivering 17 to 18
litres of binder per minute.
• Lance: It shall have a 5,0 m oil resistant delivery hose fitted to a 1,0 m lance including handle grip, shut off valve and two 65° flat spray
adjustable nozzles.
• Heating: Ideally sized burner ring, gas regulator, air control valve, heat deflector shield and gas bottle carrying bracket.
B10.1.6.2 Chip spreading equipment

a) Using spotting and hand spreading:
A half 210 litre drum (105 litre) with the bottom removed and two handles fitted to the side of the drum will be used for spotting of the chips prior to hand
spreading by shovel.
b) Using a manually operated chip spreader:
When used in place of spotting and hand spreading, the manually operated chip spreader shall be capable of spreading stone of the specified size
uniformly over the specified width. It shall be capable of adjustment to permit variation of the rate of application within the specified tolerances and uniform
spreading in both the transverse and longitudinal directions.

B 10.1.6.3 Slurry mixer
Mixing of the slurry may be done with any suitable equipment capable of producing a uniform consistency.
B10.1.6.4 Rollers
Sufficient suitably sized (± 1 ton) tandem vibratory pedestrian rollers having two equally sized drums in tandem with both drums driven, each drum to
have a separate eccentric shaft, shall be available and used to properly place the stone.
B10.1.6.5 Brooms
Sufficient hand-held brooms shall be available and used to further distribute the chips evenly as directed by the Engineer.
B10.1.6.6 Loader for aggregate

Aggregate may be loaded and transported either by wheelbarrows or containers for which the volume can be calculated.
B10.1.6.7 Pre-coating plant

The pre-coating of chips may be done with any suitable equipment capable of uniformly coating the chips.
B10.1.6.8 Miscellaneous equipment

Sufficient equipment for handling and hauling aggregate and binder, shall be provided to ensure prompt and continuous placing and application of
bituminous materials as specified. The Contractor shall have available all the necessary ancillary equipment and hand tools to carry out the work efficiently.
Suitable protective clothing shall be worn at all times.

B10.1.8 WORKMANSHIP

C10.1 GENERAL REQUIREMENTS FOR SURFACE TREATMENTS
(i) Preamble
The tendered rate for each item shall include full compensation for providing, maintaining and decommissioning upon completion, of all the plant, equipment,
labour, tools, incidentals and supervision to carry out the activity or construct the works in the item, unless otherwise stated.
Any prime cost or provisional sums shall be paid in accordance with the provisions of the conditions of contract. The charge or mark-up tendered or
allowed for is a percentage of the amount actually paid under the prime cost or provisional sum. This percentage shall cover all the Contractor’s handling,
supervision, profit and liability costs to provide the services in the prime cost or provisional sum item.
Where pay item descriptions include any wording in brackets it is an indication that contract specific information is to be inserted in the Pricing Schedule
included in the Contract Documentation.
The following activities, whether required to complete the specified work or not, will not be measured and paid for separately and the Contractor shall
include the cost thereof in other pay items as he deems appropriate:
areas. Any additional costs associated with working in confined or restricted areas shall be deemed to be included in the standard applicable pay
items.
C10.1.1 Single seals including a cover spray, if specified (indicate grade of aggregate and type
of binder):
C10.1.1.1 Using 5,0 mm aggregate square metre (m²)
C10.1.1.3 Using 10 mm aggregate square metre (m²)

Single seals including a cover spray, if specified (indicate grade of aggregate and type
C10.1.2
of binder) spreading the aggregate by (state: walk behind spreader or by hand):
The unit of measurement shall be square metre of completed and accepted seal in accordance with the approved method statement and additional
instructions.
The nominal rates for single seals indicated in Table A10.1.3-3 shall apply.

The tendered rates shall include full compensation, inter alia, for furnishing all materials, marking the centre line or reference lines, spraying of binder,
spreading of aggregate, rolling, removing of dust or deleterious material, supplying of water and spraying of haul roads and construction roads, trimming
the edges of the completed surface, and all other incidentals necessary for completing the work as specified, except the precoating of aggregate, which
shall be paid for separately.
C10.1.3 Multiple stone seals including a cover spray, if specified using:

C10.1.3.1 20 mm and 10 mm aggregate (state grade of aggregate and type of binder to be used for square metre (m²)
each layer)
C10.1.3.2 20 mm and 7,1 mm aggregate (state grade of aggregate and type of binder to be used for square metre (m²)
each layer)
each layer)
each layer)
C10.1.3.5 20 mm with a split application of 7,1 mm aggregate (state grade of aggregate and type of square metre (m²)
binder to be used for each layer)
The unit of measurement shall be the square metre of completed and accepted seal in accordance with the approved method statement and additional
instructions.
The nominal rates for multiple stone seals indicated in Tables A10.1.3-4 and A10.1.3-5 shall apply. The tendered rate shall include full compensation inter
alia, for furnishing all materials, marking the centreline, spraying of binder spreading of aggregate, rolling, removing of dust or deleterious material,
supplying of water and spraying of haul roads and construction roads, trimming the edges of the completed surface, and all other incidentals necessary
for completing the work as specified, including the application of a fog spray, except the precoating of aggregate, which shall be paid for separately.
C10.1.4 Embargo period effects
C10.1.4.1 Re-establishment of sealing team after embargo period lump sum
C10.1.4.2 Extra-over for sealing during the specified embargo period (State seal type, binder for each square metre (m²)
layer)
Payment for the rate tendered under item C10.1.6.1 only be applicable when sealing has to cease due to commencement of the embargo period as
specified, and due to any approved extension of time not due to the to that originally specified. The tendered rate shall include for all costs associated
with re-establishing all necessary plant and equipment in order to complete the works.
The rate tendered under item C10.1.6.2 shall only be applicable if the seal, as specified, cannot be constructed due to commencement of any winter
embargo period and where such a situation is due to legitimate and approved extensions of time or sealing during the embargo period is specified in the
Contract documentation. The rate tendered shall include for all costs associated with construction the surfacing with any appropriate binder type, reduced
production rates, increased traffic accommodation measures and obligations.
C10.1.5 Sand or Grit seals using:
C10.1.5.1 Sand seal (state grades of aggregate and types of binders to be used) square metre (m²)
C10.1.5.2 Grit seal (state grades of aggregate and types of binders to be used) square metre (m²)
C10.1.6 Sand or Grit seals using (state: walk behind spreader or by hand):
C10.1.6.1 Sand seal (state grades of aggregate and types of binders to be used) square metre (m²)
C10.1.6.2 Grit seal (state grades of aggregate and types of binders to be used) square metre (m²)
instructions.
The nominal rates for sand and Grit seals indicated in Table A10.1.3-6 shall apply.
The tendered rate shall include full compensation inter alia, for furnishing all materials, marking the centreline, spraying of binder spreading of aggregate,
rolling, removing of dust or deleterious material, supplying of water and spraying of haul roads and construction roads, trimming the edges of the completed
surface, and all other incidentals necessary for completing the work as specified, except the precoating of aggregate, which shall be paid for separately.

C10.1.7 Graded aggregate (Otta) seals using:
C10.1.7.1 Single minus 20 mm aggregate (state grades of aggregate and types of binders to be used) square metre (m²)
square metre (m²)
C10.1.7.3 Single minus 10 mm aggregate (state grades of aggregate and types of binders to be used)
square metre (m²)
C10.1.7.4 Extra over for sand seal (state grades of aggregate and types of binders to be used)
C10.1.8 Graded aggregate (Otta) seals, with aggregate applied by hand, using:
square metre (m²)
C10.1.8.3 Single minus 10 mm aggregate (state grades of aggregate and types of binders to be used)
square metre (m²)
C10.1.8.4 Extra over for sand seal (state grades of aggregate and types of binders to be used)
instructions.
The nominal rates for Graded aggregate seals as indicated in the Contract Documentation shall apply.
The tendered rate shall include full compensation inter alia, for furnishing all materials, marking the centreline, spraying of binder spreading of aggregate,
rolling, removing of dust or deleterious material, supplying of water and spraying of haul roads and construction roads, trimming the edges of the completed
surface, and all other incidentals necessary for completing the work as specified
C10.1.9 Bituminous binder variations:
C10.1.9.1 70/100 Penetration grade bitumen litre (ℓ)
C10.1.9.2 60 % Stable-grade emulsion litre (ℓ)
C10.1.9.3 Cationic Stable grade emulsion ((indicate bitumen content) litre (ℓ)
C10.1.9.4 Cationic Spray-grade emulsion (indicate bitumen content) litre (ℓ)
C10.1.9.5 Homogeneous modified binder (indicate type and bitumen content) cold applied litre (ℓ)
C10.1.9.6 Non-homogeneous modified binder (indicate class S-R1 or S-R2) litre (ℓ)
C10.1.9.7 Homogeneous modified binder (indicate type) hot applied litre (ℓ)
C10.1.9.8 Homogeneous modified binder S-E1 with 4,5% MC30 litre (ℓ)
C10.1.9.9 Homogeneous modified binder S-E1 with 9% MC30 litre (ℓ)
C10.1.9.10 MC-3000 cut-back bitumen litre (ℓ)
C10.1.9.11 Precoating fluid (state type) litre (ℓ)
The unit of measurement for bituminous binder in respect of an increase or a decrease in the specified rates of application shall be the litre measured at
spraying temperature (except for diluted emulsions, where the variation is calculated in terms of the emulsion before dilution)
Where MC30 is used to cut back the penetration-grade bitumen, the rate for MC-30 variation shall include full compensation for providing the MC-30 and
mixing it with the bituminous binder.
C10.1.10 Aggregate variation (state grade):
C10.1.10.1 5,0 mm aggregate cubic metre (m³)
C10.1.10.2 7,1 mm aggregate cubic metre (m³)

C10.1.10.3 10 mm aggregate cubic metre (m³)
C10.1.10.6 Sand cubic metre (m³)
C10.1.10.7 Grit cubic metre (m³)
The unit of measurement for aggregate in respect of an increase or a decrease in the rates of application determined during the trial sections and
contained in the approved method statement, shall be the cubic metre of aggregate.
C10.1.11 Application of cover spray:
C10.1.11.1 60 % Anionic Stable-grade emulsion litre (ℓ)
C10.1.11.2 60 % Diluted Anionic stable-grade emulsion (indicate dilution in % emulsion/%water) litre (ℓ)
C10.1.11.3 Diluted Cationic spray-grade emulsion (indicate % bitumen and dilution in % emulsion/%water) litre (ℓ)
C10.1.11.4 Diluted SC-E1 (indicate % bitumen and dilution in % emulsion/%water) litre (ℓ)
This pay item shall only apply when an additional cover spray is ordered by the Engineer. Cover sprays included as part of the seal design shall be
deemed to be included in the total rate for the pay item of the specific seal.
The nominal rates for cover sprays seals indicated in Clause A10.1.3.15 shall apply.
The unit of measurement shall be the litre of undiluted/diluted emulsion as specified, measured at spraying temperature.
The tendered rate shall include full compensation for furnishing the material and applying the cover spray as instructed.
C10.1.12 Application of cover spray by hand:
C10.1.12.1 60% Anionic Stable-grade emulsion litre (ℓ)
C10.1.12.2 60% Diluted Anionic Stable-grade emulsion (indicate dilution in % emulsion/%water) litre (ℓ)
C10.1.12.3 Diluted Cationic Spray-grade emulsion (indicate % bitumen and dilution in % emulsion/%water) litre (ℓ)
C10.1.12.4 Diluted SC-E1 (indicate % bitumen and dilution in % emulsion/%water) litre (ℓ)
This pay item shall only apply when an additional cover spray is ordered by the Engineer. Cover sprays specified as part of the seal are included in the
pay item of the specific seal.
The nominal rates for cover sprays seals indicated in Clause A10.1.3.15 shall apply.
The unit of measurement shall be the litre of diluted/undiluted emulsion as specified, measured at spraying temperature.
The tendered rate shall include full compensation for furnishing the material and applying the cover spray as instructed.
C10.1.13 Precoating of aggregate using a dedicated plant
C10.1.13.1 Product containing low flashpoint solvent (indicate precoating fluid) litre (ℓ)
C10.1.13.2 Product containing no low flashpoint solvent (indicate precoating fluid) litre (ℓ)
C10.1.14 Precoating of aggregate using a frontend loader

C10.1.15 Precoating of aggregate by hand
The unit of measurement for the precoating of aggregate shall be the litres of precoating fluid for treatment of the specified aggregate in accordance
with the specified precoating method.
The nominal rates for precoating fluid as indicated Table A10.1.3-9 (non-plant) shall apply.
The tendered rate shall include full compensation for furnishing the equipment and materials and precoating the aggregate as specified, including the
handling, stockpiling and protecting of the stockpiles against inclement weather.
C10.1.16 Addition of wetting agent:
C10.1.16.1 Providing and supplying prime-cost sum

percentage of prime-cost sum
C10.1.16.2 Handling, applying, profit and all other costs
Prime cost sum will be paid for in terms of the general conditions of contract for providing and supplying an approved wetting agent to the precoating fluid
as specified or as directed by the Engineer.
The tendered percentage of the prime cost sum shall include full compensation for handling the material, storing and introducing it into the mix, including
any equipment required and for all other charges and profit.
C10.1.17 Aggregate for blinding:
C10.1.17.1 Natural sand cubic metre (m³)
C10.1.17.2 Crusher sand cubic metre (m³)

The unit of measurement shall be the cubic metre of sand measured in the hauling vehicles.
The tendered rate shall include full compensation for providing the material and applying the blinding coat complete as specified, and, should it be
required, stockpiling the sand at an approved locality.
C10.1.18 Aggregate for blinding by hand:
C10.1.18.1 Natural sand cubic metre (m³)
C10.1.18.2 Crusher sand cubic metre (m³)

The unit of measurement shall be the cubic metre of sand measured in the hauling vehicles.
The tendered rate shall include full compensation for providing the material and applying the blinding coat complete as specified and should it be required,
stockpiling the sand at an approved locality.
C10.1.19 Extra over item for work in areas inaccessible to mechanical equipment:
C10.1.19.1 Single seals square metre (m²)
C10.1.19.2 Multiple stone seals square metre (m²)
C10.1.19.3 Cape seals with one layer of slurry square metre (m²)
C10.1.19.4 Cape seals with two layers of slurry square metre (m²)
C10.1.19.5 Graded aggregate seals square metre (m²)
C10.1.19.6 Sand and Grit seals square metre (m²)
C10.1.19.7 Conventional slurry square metre (m²)

C10.1.19.8 Microsurfacing square metre (m²)
C10.1.19.9 Adding Grit or slurry to single seals on areas subjected to traffic turning and breaking actions
or localised cold areas:
(a) Application of diluted emulsion (State type, % bitumen and dilution) litre (ℓ)
(b) Applying Grit cubic metre (m³)
(c) Applying Texture slurry cubic metre (m³)

The tendered rate shall include full compensation for all additional costs to execute the work in areas inaccessible to mechanical equipment.
Payment will not distinguish between the various types of binders or various sizes or grades of aggregate.
C10.1.20 Supply and application of geosynthetic membrane:
C10.1.20.1 Supply and application of geosynthetic membrane (state type) square metre (m²)
C10.1.21 Slurry and microsurfacing:
C10.1.21.1 Conventional slurry (indicate type and grade of binder and grade of aggregate) cubic metre (m3)
C10.1.21.2 Microsurfacing (indicate type and grade of binder and grade of aggregate) cubic metre (m3)
The unit of measurement for slurry and microsurfacing shall be the cubic metre of saturated fine aggregate as determined according to the method described
in Clause A20.1.5.13 of Chapter 20.
The nominal rates for slurry and microsurfacing as per Clause A10.1.3.14 shall apply.
The tendered rates shall include full compensation, for furnishing all materials, demarcating the working area, mixing and applying the slurry, rolling and
all other incidentals necessary for completing the work as specified, including the watering of haul and construction roads in and about the site.
C10.1.22 Bituminous single seal and slurry, including a cover spray if specified:
C10.1.22.1 Bituminous single seal with 20 mm aggregate and first slurry (indicate type of tack coat and square metre (m²)
cover spray binder and grade of aggregate)
C10.1.22.2 Bituminous single seal with 14 mm aggregate and slurry (indicate type of tack coat and square metre (m²)
cover spray binder, grade of aggregate and grade of slurry)
C10.1.22.3 Bituminous single seal with 10 mm aggregate and slurry (indicate type of tack coat and square metre (m²)
cover spray binder, grade of aggregate and grade of slurry)
C10.1.22.4 Extra over C10.1.22.1 for application of second slurry (State grade of slurry) square metre (m²)
The unit of measurement for the complete bituminous single seal with aggregate and slurry shall be the square metre.
The nominal rates for single seals and slurry as per Clause A10.1.3.14 shall apply.
The tendered rates shall include full compensation, for furnishing all materials, demarcating the working area, spraying the binders, spreading the
aggregates, rolling, mixing and applying the slurry, and all other incidentals necessary for completing the work as specified, including the watering of haul
and construction roads in and about the site.
The cost of providing the slurry seal over the final primed width shall be included in the rate for providing the seal with slurry over the bituminous surfaced
width
C10.1.23 Slurry-bound macadam seal:

C10.1.23.1 Slurry-bound macadam seal with 14 mm aggregate and slurry (indicate thickness and grade square metre (m²)
of aggregate)
of aggregate)
of aggregate)

The unit of measurement for the complete slurry-bound macadam seal with aggregate and slurry shall be the square metre. The nominal rates for slurry-bound
macadam seals as per Clause A10.1.3.14 shall apply.
The tendered rates shall include full compensation, for furnishing all materials, demarcating the working area, spraying the binders, spreading the
aggregates, rolling, mixing and applying the slurry, and all other incidentals necessary for completing the work as specified, including the watering of haul
and construction roads in and about the site.
C10.1.24 Variation in the rate of application of the fine slurry:
C10.1.24.1 Fine grade cubic metre (m3)
C10.1.24.2 Medium grade cubic metre (m3)
The unit of measurement for slurry variations shall be the cubic metre of saturated fine aggregate.
Payment for variations shall be made as specified in C1.1.4 of Chapter 1.
C10.1.25 Variation in active filler content (specify active filler) ton (t)
The unit of measurement in respect of increases or decreases in the active filler content from that specified in the nominal mix for tender purposes shall
be the ton. No payment shall be made for inert filler added by the Contractor.
Payment for variations shall be made as specified in C1.1.4 of Chapter 1.
C10.1.26 Trial sections for all seal types specified (specify seal type) Lump sum
The tendered rates shall include full compensation, for furnishing all materials, demarcating the working area, constructing the seal, and all other incidentals
necessary for completing the work as specified.
C10.1.27 Provision of Performance Guarantee in respect of the Surfacing Lump sum
The tendered rate shall include the provision of a bank guarantee in respect of the Surfacing, for an amount equal to 10 % of the contract value, valid for
a period of two (2) years from Completion. The terms and conditions applicable to the release of the guarantee shall be as described under Clause
D10.1.7. The guarantee shall be valid for two years, after the issuing of the Completion Certificate.
The performance guarantee as required shall be delivered to the Employer by the successful Contractor before signing of the contract with the applicable
date of commencement of validity of the guarantee stated to be from the Completion Certificate and its estimated date.
The guarantee shall be prepared to the format provided in the Contract Documentation. The terms of the conditions applicable to the release of the
performance guarantee shall be as described under Clause D10.1.3.
The tendered lump sum shall not be subject to Contract Price Adjustment and shall become payable once the Contractor has submitted and the Employer
has accepted the guarantee.

square metre (m²)
C10.1.28 Surfacing (state type and binders)
The unit of measurement shall be the square metre of surfacing constructed within specifications.
The tendered rate shall include full compensation for materials and construction as well as for process-control testing, and for protecting and maintaining
the work, all as specified.

D10.1 GENERAL REQUIREMENTS FOR SURFACE TREATMENTS
CONTENTS
D10.1.1 SCOPE
D10.1.2 GENERAL
D10.1.1 SCOPE
This Section covers the specifications and work related to the functional and structural condition of the bituminous surface treatment (surfacing seal) in
terms of a performance guarantee to be provided by the Contractor, valid for the specific period from the issue of a Completion Certificate for the whole
of the Works. It includes performance parameters, field measurements, acceptance criteria and remedial work methodologies.
D10.1.2 GENERAL
This specification supplements Clause A10.1.4.

The surfacing shall be constructed in terms of a performance guarantee. The performance guarantee, in the form of a financial guarantee, shall be limited
to the performance of the surfacing, only. With the exception of de-bonding between the surfacing and the substrate, the Contractor shall not be held
liable for any failures of the surfacing that might occur as a result of failure within the underlying layers. During the Performance Period, the Contractor
shall also not be held liable for any damage to the surfacing resulting from “outside” sources, including, but not limited to:
• Traffic accidents
• Spillage of fuel, oils, hazardous materials, etc.
• Materials falling off vehicles
• Travelling of construction/tracked plant (other than his own) after completion of the Works.
Prior to the issuing of the Completion Certificate, the Contractor shall provide a guarantee, valued at 10 % of the cost of the surfacing as measured under
item C10.1.25 for the performance of the surfacing layer. The guarantee shall be issued by a bank or other institution approved by the Employer and shall
become effective on issue of the Completion Certificate. It shall remain valid until released in terms of Table D10.1.3-1.
The programme for the release of the guarantees shall be as follows:
Table D10.1.3-1: Program for release of guarantees
Time Activity
Provision of one guarantees (10 %)
Completion of Works and issue of the Taking-Over
Certificate Payment of 50 % of retention (as per sub-clause 14.9
of GCC)
Payment of balance of retention to be released upon
Acceptable performance of Works one year after
issuing of Performance Certificate (as per sub-clause
issuing of the Completion Certificate
14.9 of GCC)
Acceptable performance of the surfacing two
Release of guarantee (10 %)
years after issuing of the Completion Certificate

The monitoring of the functional performance of the Surfacing seal shall be by the visual assessment of functional performance parameters and
instrumental assessment of macro texture immediately after completion (prior to the issue of the Completion Certificate), and then by the visual and
instrumental assessments of the relevant parameters at the ends of years 1 and 2 after the issuing of the Completion Certificate.
The Employer may, at his sole discretion, omit the assessment programme for the end of year 2 if, in his opinion, there is no evidence of any non-
conformance to the specified criteria. The functional performance parameters to be assessed are listed in Table D10.1.4-1 for both visually - as well as
instrumentally - assessed parameters.
Table D10.1.4-1: Functional performance parameters for surfacing seals
Visually-assessed parameters Instrumentally-assessed parameters
1. Surface failure (de-bonding) 1. Surface macro-texture
2. Surface cracking
3. Surface ravelling (aggregate loss)
4. Bleeding
The functional performance assessments undertaken in years 1 and 2 after the issuing of the Completion Certificate shall, as far as practicably possible,
coincide with the Employer’s regular road-assessment programme within those years. The roughness and surface macro-texture surveys will be
commissioned, and the costs thereof will be borne, by the Employer.

D10.1.5.1 Definition
The detailed description and definition for the visually-assessed parameters and the degree of a visually-assessed parameters, as specified in TMH 9
Manual for Visual Assessment of Road Pavements PART A and PART B: issued by the Committee of Transport Officials (COLTO), May 2016.Assessment
methodology, shall apply
The visual assessments of the pavement surfacing during the Performance Period shall be undertaken by means of a Visual-Assessment Panel
comprising the following representatives:
• Employer: 1 representative
• Contractor: 1 representative
• Engineer or suitably qualified external assessor: 1 representative
All site investigations or inspections shall be undertaken by the panel of representatives. The arrangements, responsibilities and costs for such inspections
shall vest with the Contractor, but he shall not be responsible for the travel, accommodation and personnel costs of the Employer and Engineer during the
panel inspections. The visual assessments shall be carried out during daylight hours in off-peak periods.
D10.1.5.2 Assessment specification

A detailed visual-assessment (walk over) by the assessment panel will quantify each occurrence of the visually-assessed parameters by rating the degree
of distress according to the TMH 9 definitions and the extent as the linear length (in metres) affected in the direction of travel. The minimum linear length
to be recorded for any single occurrence of any of the visually-assessed parameters shall be 0,5 m. Visual assessments must be done in accordance
with the specification presented in Table D10.1.5-1.
Table D10.1.5-1: Specification for visual assessment
Item Specification
Frequency of assessment Immediately after completion, and then in years 1, 2 and 3 after the issuing of the Taking-
Over Certificate and coinciding with the Employer’s regular road-assessment programme.
Position of assessment Each lane and shoulder shall be individually assessed.
Segment lengths 1,0 km
Degree As defined in TMH 9.
Extent The actual length affected, with a minimum recorded linear length per single occurrence
of 0,5 m.
D10.1.5.3 Data processing and reports

For each of the visually-assessed parameters the Combined Index Value will be calculated for every 1,0 km segment of each lane and shoulder. The
Combined Index Value (CIV) for each visually-assessed parameter will be processed as follows:

5 (Length )
Combined Index Value (CIV ) = 
Degree=1
Degree
10
Degree
   Length 2   Length 3   Length 4   Length 5 

1  Length1  +  2  + 3 
 + 4   + 5  
 10   10   10   10   10 
       
Where Length1 = Total linear length (in metres) of degree 1 distress over the 1 km segment, etc.
The processed results shall be used to produce results in the format specified in Table D10.1.5-2.
Table D10.1.5-2: Specification for output of visual assessments

Item Specification
Unit Combined Index Value (CIV)
Segment lengths 1,0 km
Statistical summary Produce Combined Index Value (CIV) for each lane and shoulder
Reporting, which shall be the responsibility of the Contractor, shall consist of the following:
- Completion and copying of report forms according to Employer’s format.
- Compiling of report on findings as well as remedial measures required.
The abovementioned requirements shall be completed and delivered in triplicate to the office of the Employer within one calendar month of the inspection
date.
D10.1.5.4 Acceptance criteria

The visually-assessed parameters as well as the calculated Combined Index Value shall meet the Acceptance Criteria listed in Table D10.1.5-3 for the
applicable year of survey.
Table D10.1.5-3: Acceptance criteria for visually-assessed distress on surfacing seals
Maximum Allowable
Type of Distress Time 1 (Years)
Degree2 CIV3
1 1 0.0
Surface failure
2 2 0.1
(de-bonding)
3 2 0.2
1 1 1.0
Surface cracking 2 2 2.0
3 2 3.0
1 1 0.0
Surface ravelling 2 2 1.0
3 3 3.0
1 1 0.0
Bleeding 2 2 1.0
3 2 3.0
Notes:
1. Time in years after the issuing of the Taking-Over Certificate.
2. The degree of a visually-assessed parameter as specified in TMH 9 Manual for Visual Assessment of Road Pavements PART A and PART B: issued
by the Committee of Transport Officials (COLTO), May 2016.
3. Combined Index Value (CIV) per one kilometre length of lane or shoulder.

D10.1.6.1 Surface macro-texture
a) Definition
Macro-texture is the deviation of a pavement surface from a true planar surface with the characteristic dimensions along the surface of 0,5 – 50 mm.

b) Equipment and accuracy
The macro-texture in terms of Mean Profile Depth (MPD) shall be measured in accordance with the procedure described in Chapter 20.
c) Validation and operation
Validation and operation of the non-contact laser spot sensor must be carried out in accordance with the manufacturer’s requirements, and it must have
successfully completed the validation trials of the Employer not more than six months before the measurements are taken in accordance with these
specifications.
d) Measurement specification
Macro-texture measurements must be taken in accordance with the specification presented in Table D10.1.6-1.
Table D10.1.6-1: Specification for measurement of surface macrotexture
Item Specification
Frequency of measurement Between 7 and 14 days after opening to traffic, and then after year 1 and 2 of the
performance period, coinciding with the Employer’s regular road-assessment
programme.
Position of measurement Both wheel paths and in-between wheel paths of all trafficked lanes.
Testing intervals Record data over 10m intervals.
e) Data Processing and Reports

Surface macro-texture data must be processed so as to produce results in the format specified in Table D10.1.6-2.
Table D10.1.6-2: Specification for output of surface macro-texture
Item Specification
Unit Mean Profile Depth (ISO 13473-1) calculated for each 10 metres.
Segment lengths 1 km
Statistical summary Produce cumulative distribution graph for each segment
f) Acceptance criteria
Using the cumulative distribution graph for each segment, the measured surface macro-texture must meet the acceptance criteria presented in Table
D10.1.6-3.
Table D10.1.6-3: Acceptance criteria (Minimum) for initial surface macro-texture
20 Cape
14 Cape
10 mm
14 mm
20/7/7
20/10
14/7
20/7
Seal Type
5th Percentile MPD 1.8 1.95 1.5 1.8 1.55 1.7 NA NA

Notes:
The average MPD value per km lot becomes the reference MPD for performance measurement
The volumetric texture depth as determined by SANS 3001-BT11 = 1.35 times the Mean Profile Depth
Table D10.1.6-4: Acceptance criteria for surface macro-texture performance – double seals
Percentage retention of Maximum (%) of 1 km segment with
Time initial surface macro-texture retention worse
Mean profile depth (%)2 than limit value
85.0 20 %
Year 11 80.0 5%
75.0 0%
80.0 20 %
Year 21 75.0 5%
70.0 0%
Notes:
1. Time in years after the issuing of the Performance Certificate.
2. Mean Profile Depth value over 10 m.

Table D10.1.6-5: Acceptance criteria for surface macro-texture performance –single seals
Percentage retention of Maximum (%) of 1,0 km segment with
Time initial surface macro-texture retention worse
Mean profile depth (%)2 than limit value
70.0 20%
Year 11 60.0 5%
55.0 0%
60.0 20%
Year 21 55.0 5%
45.0 0%
Notes:
1. Time in years after completion.
2. Mean Profile Depth value over 10 m.

The following procedures shall be followed by the Engineer to determine the acceptance of the surfacing or to determine whether remedial work is required
on it. These procedures shall be followed as appropriate after each of the assessments.
D10.1.7.1 Assessment on completion of the works

An assessment shall be done on completion of the Works and the Contractor shall repair all defects recorded.
The first 50% of the Retention Money will be released subject to the further requirements of sub-clause 14.9 of the FIDIC Conditions of Contract.
D10.1.7.2 Assessment one year after completion in performance period

Should all parameters meet the full Acceptance Criteria at the end of the Defects Notification Period, the Engineer shall issue a report to the Employer
and notify the Contractor accordingly. The balance of the Retention Money will be released.
Should the full Acceptance Criteria not be met, the Engineer shall advise the Contractor of such defects as may be evident and may, in consultation with
the Employer, either:
a) Instruct the Contractor to undertake immediate remedial work.
b) Grant a concession to allow the remedial work to be held in abeyance until further notices are issued by the Engineer.
c) Notwithstanding the concessions that may be granted under b) above, the Contractor may elect to attend to and defects immediately.
D10.1.7.3 Assessment two (2) years after completion in performance period

Should all parameters meet the full Acceptance Criteria two years after completion, the Engineer shall issue a report to the Employer and notify the
Contractor accordingly and the Performance Guarantee shall be released to the Contractor. The Contract shall then be complete and the Contractor shall
then have no further liability for the performance of the works, except for unfulfilled obligations as provided for under clause 11.10 of the FIDIC Conditions
of Contract.
Should the full Acceptance Criteria not be met, the Engineer shall advise the Contractor of such defects as may be evident and may, in consultation with
the Employer, either:
a) Instruct the Contractor to undertake remedial work in accordance with Clauses D10.1.8, D10.1.9 and D10.1.10.
b) Establish a fair valuation of the costs or damages that may be incurred due to the defective work and request payment of such amounts from the
Contractor. Once such payments have been received the Performance Guarantee shall be released to the Contractor.
c) The Contractor may elect to undertake all outstanding remedial work, which shall be undertaken in accordance with Clauses D10.1.8, D10.1.9 and
D10.1.10. Upon satisfactory completion of such remedial work and acceptance by the Engineer and the Employer, the Performance Guarantee shall
be released to the Contractor
Once the conditions stated under either a), b) or c) above have been met, the Contract shall be complete and the Contractor shall then have no further
liability for the performance of the Works.
D10.1.7.4 Assessment at any time during the Performance Period

The Employer or the Engineer shall be entitled to carry out an assessment of the work at any time during the Performance Period. Should any parameter/s
fall into the remedial-work-required category, the Employer or his agent shall inform the Contractor who shall immediately propose a solution to rectify the
problem/s and obtain the Employer's or his agent's approval and rectify the problem/s in accordance with Clauses D10.1.8, D10.1.9 and D10.1.10.

In addition to procedures described in Clause D10.1.7 the following shall apply:
a) The Engineer's approval shall be obtained prior to the Contractor's carrying out any remedial work. Notwithstanding the approval by the Engineer of
the remedial work, the Contractor shall remain fully liable for the performance of his proposed remedial action/s measured in terms of the specified

performance parameters.
b) Lane rental shall be applicable when repair work is undertaken by the Contractor during the Performance Period at the rates specified in the Contract
Documentation.
c) In the event of the Contractor's failing to undertake the required steps to rectify/reinstate any defects to conform with the specified requirements, the
Employer reserves the right to withhold payment of any monies which are payable to the Contractor or which may become payable to him under the
Contract.

The Employer or his agent shall notify the Contractor in writing of any remedial work or repairs required to the surfacing in terms of this section of the
specifications. Such notification shall take place at any time during the Performance Period, but at least after each year of the Performance Period.
The Contractor shall search and find the cause and mechanism of failure and propose appropriate remedial actions within fourteen (14) days of the date
of such notification.
Following acceptance by the Employer, a programme of work must be submitted for approval to the Employer or his agent within fourteen (14) days of
the date of such acceptance.
The Contractor shall commence with the remedial work within thirty (30) days from the date on which the site is handed to him by an order in writing from
the Engineer.

All remedial work or repairs to the surfacing shall comply with the following requirements:
a) The Contractor shall, at his own cost, supply, erect and maintain the necessary temporary traffic-control signs in accordance with the requirements
in the Contract Documentation and the latest version of the South African Road Traffic Signs Manual,
b) The Contractor shall, also at his own cost, repair/reinstate such items as road studs, road marking, etc., should these be damaged or influenced by
the required remedial work.
c) The various types of remedial work contained in Table D10.1.10-1, depending on the degree of distress, shall be undertaken by the Contractor, at
his own cost, to reinstate/rectify specified defects in the pavement surfacing during the specified Performance Period.
Final acceptance shall only be given upon completion of all remedial works to the satisfaction of the Employer and the Engineer.
Table D10.1.10-1: Remedial work for surfacing seals
Type of Distress Acceptance Criteria Minimum Remedial Measures
Surface Failure Requirements in Table D10.1.5-3 not met Mill out full depth of defective surfacing and replace with
suitable asphalt surfacing
Surface Cracking Requirements in Table D10.1.5-3 not met Investigation
Surface Ravelling Requirements in Table D10.1.5-3 not met Application of a fog spray and slurry texture treatment
Bleeding Requirements in Table D10.1.5-3 not met Water cutting of surfacing
Surface Macrotexture Requirements in Table D10.1.6-4 and Table D10.1.6-5 not Water cutting of surfacing
met

South Africa
COTO
Officials

DRAFT
Draft Standard (DS)

CHAPTER 11: ANCILLARY ROAD
WORKS
October 2020

FOREWORD

Published by:
The document with its Chapters is provided as a Draft Standard (DS) without any warranty of any kind, expressed or implied. No
warranty or representation is made, either expressed or implied, with respect to fitness of use and no responsibility will be

industry.
Document versions:
COTO subcommittee. The document is converted to a Final Standard (FS) and submitted by the Roads Coordinating Body (RCB)
to COTO for approval as a final standard. This Final Standard is implemented in industry for a period of five (5) years, after which
it may again be reviewed. Final Standards (FS) have full legal standing.
Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 11: ANCILLARY ROAD WORKS .......................................................................................................... 11-1
11.1 PITCHING, STONEWORK, CAST IN SITU CONCRETE FOR PROTECTION AGAINST EROSION ....... 11-1
PART A: SPECIFICATIONS ............................................................................................................................................................................. 11-1
PART B: LABOUR ENHANCEMENT ................................................................................................................................................................ 11-6
11.2 NON-STRUCTURAL GABIONS ................................................................................................................ 11-12
PART A: SPECIFICATIONS ........................................................................................................................................................................... 11-12
PART B: LABOUR ENHANCEMENT .............................................................................................................................................................. 11-15
11.3 GUIDE BLOCKS AND KILOMETRE MARKERS ...................................................................................... 11-20
11.4 ROAD RESTRAINT SYSTEMS ................................................................................................................. 11-28
11.5 FENCING .................................................................................................................................................... 11-41
11.6 ROAD SIGNS ............................................................................................................................................. 11-53
11.7 ROAD MARKINGS AND ROAD STUDS ................................................................................................... 11-68
11.8 LANDSCAPING AND PLANTING PLANTS .............................................................................................. 11-82
11.9 FINISHING THE ROAD AND ROAD RESERVE AND TREATING OLD ROADS .................................... 11-97
PART C: MEASUREMENT AND PAYMENT ................................................................................................................................................ 11-100
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES ................................................................................................................... 11-102
CHAPTER 11: ANCILLARY ROAD WORKS
11.1 PITCHING, STONEWORK, CAST IN SITU CONCRETE FOR
PROTECTION AGAINST EROSION
CONTENTS
A11.1.1 SCOPE
A11.1.2 DEFINITIONS
A11.1.3 GENERAL
A11.1.5 MATERIALS
A11.1.7 EXECUTION OF WORKS
A11.1.8 WORKMANSHIP

A11.1 PITCHING, STONEWORK, CAST IN SITU CONCRETE FOR PROTECTION

AGAINST EROSION
A11.1.1 SCOPE
This Section covers the furnishing of materials and the construction of protective coverings using stone, cast in situ concrete, bricks, prefabricated
concrete elements, wire or alternative materials on exposed surfaces such as earth slopes, drains and stream beds, as well as heavier protective
layers in the form of riprap and the construction of stone masonry for walls, as specified and shown on the drawings, or as specified in the Contract
Documentation.
A11.1.2 DEFINITIONS
A11.1.3 GENERAL
No general items.

None applicable.
A11.1.5 MATERIALS
The material specifications are the required specifications for the materials as placed and/or processed in its final position within the road reserve.
It remains the Contractor’s responsibility to ensure that the materials delivered to the road shall meet these specified requirements

A11.1.5.1 Stone
Stone for pitching shall be sound, tough and durable, without any stones less than 200 mm in minimum dimension, except that smaller pieces or
spalls may be used for filling spaces between the larger stones. The shapes of the rocks or stones shall be so as to form a stable protective layer
of the required thickness. Rounded boulders shall not be used on slopes steeper than 2:1 unless cement grouted. Unless suitable stone can be
located on site, the stone for pitching shall be procured from commercial sources but, from whatever source, it shall be subject to the prior approval
of the Engineer.
Stone for masonry walls shall have a minimum mass of 8,0 kg for each stone, except that smaller pieces or spalls may be used for filling spaces
between the larger stones. Stones shall have a minimum vertical dimension of 75 mm and have a flat and stratified shape if locally available.
Stone for riprap shall be hard field or quarry stone of angular shape, not susceptible to disintegration or excessive weathering on exposure to the
atmosphere or water. It shall be free from soft material such as sand, clay, shale or organic material and shall not contain an excessive quantity
elongated stones.
The required size of the stone will depend on the "critical mass" specified. At least 50 % by mass of the material comprising the riprap shall consist
of stones with a mass heavier than the critical mass, and not more than 10 % by mass of the material shall consist of stones with a mass of less
than 10 % of the critical mass or more than 5 times the critical mass.
A11.1.5.2 Sand
a) Sand for concrete
Sand for concrete, cement slurry and cement mortar shall comply with the requirements of SANS 1083. This sand can be from natural sources,
crushed or obtained from commercial sources.
A11.1.5.3 Grass blocks

Concrete grass blocks shall consist of concrete slabs of the dimensions and strength class shown on the drawings, with openings through the slab
totalling at least 20 % of the surface area.
A11.1.5.4 Concrete and mortar

All concrete work shall be carried out in accordance with the requirements of Section A13.4 of Chapter 13, read together with the provisions of this
Section. Cement shall comply with SANS 50197-1 for CEM I or CEM II with a strength class of 32.5 or greater, and a rate of strength gain of N or
greater.
Unless the Contractor obtains the concrete from a commercial concrete supplier, the Contractor shall be responsible for providing suitable materials,
determining the mix proportions and manufacturing the concrete of the required quality to comply with SANS 50206.
strength so that, considering the expected variability of the concrete and test procedures, no more than 5 % of strength tests will be expected to fall
below the specified characteristic compressive strength.
Where concrete is supplied by a commercial source outside the direct control of the Engineer, the concrete supplier shall ensure compliance with the
requirements of SANS 50206 (SANS 878), and the Contractor shall have full responsibility to implement acceptance control testing in accordance
with the specification.
Unless otherwise specified, mortar shall consist of a mixture of six parts of concrete sand to one part of cement.
Concrete and mortar shall be properly mixed to a uniform consistency. The total period between the time that the cement is placed into the mix
until mixing starts shall not exceed 15 minutes.
Concrete and mortar shall be so transported to its final position that segregation or loss of any of the ingredients or contamination will be prevented
and that the mix is of the required workability at the point and time of placing. It shall be protected against rain, heat, direct sunlight and/or
evaporation by means of covers. No additional water may be added in transit or where delivered or placed.
Once the casting of concrete has begun, it shall be carried out in a continuous process between construction joints. Concrete shall be placed within
60 minutes from the start of mixing. This time may be extended by the Engineer where a retarding admixture has been used. All excavations and
other contact surfaces of an absorbent nature such as timber formwork shall be damp but no standing water shall be permitted to remain on these
surfaces. The formwork shall be clean on the inside.
A11.1.5.5 Permeable material for filter layer

Permeable material for filter layers shall comply with the requirements specified for permeable material for subsoil drains in Clause A3.1.5 of
Chapter 3.
A11.1.5.6 Geotextiles
Geotextiles shall be of the grade and type specified in the schedule of quantities or Contract Documentation, and shall comply with the requirements
of Section A12.11 of Chapter 12.
A11.1.5.7 Alternative materials

Alternative materials, used amongst others for the lining of drains and channels or other erosion protection, their property requirements,
construction, measurement and payment shall be specified in the Contract Documentation.

The Contractor shall submit his plant and equipment list for excavating, stockpiling if specified, loading and hauling as part of his method statement.

Where clearing and grubbing and the removal of trees is specified, it shall be executed as specified in Clause A1.6.7 of Chapter 1.
All excavations for pitching, stonework and protection against erosion shall be excavated in the position and to the required dimensions. Overbreak
in width or depth, unless specified by the Engineer, shall be in filled by the Contractor and shall not be measurable for payment.
All excavations shall be classified as follows for payment purposes:
Hard material: Material which cannot be excavated except by drilling and blasting, of with the use of pneumatic tools or mechanical
breakers,
and
Boulders exceeding 0,1 m3; where more than 40 % by volume of any material consists of boulders, each exceeding 0,1 m3
in size, the material shall be classified as hard material.
Soft material: All material not classified as hard material shall be classified as soft material.
A11.1.7.2 Stone pitching

a) Plain stone pitching
The area shall be prepared by the excavating, shaping and trimming necessary for pitching, and by thoroughly compacting the area by hand-
ramming to prevent subsequent settlement. A trench shall be excavated as specified along the toe of any slopes to be pitched or along the
unprotected edge of the pitching in the beds of streams. All loose material shall be compacted to a density of not less than 93 % of MDD. Where
the in situ material is unsuitable, the Engineer may instruct that it be removed to the required depth and replaced with selected material compacted
to a density of 93 % of MDD to the required grade and level. Where excavations for open drains are in rock, overbreak shall be backfilled as
specified, either with mass concrete or with selected gravel or soil compacted to a MDD of at least 93 %. Two pitching methods follow, and the
method to be adopted shall be specified.
Method 1
Commencing at the bottom of the trench, the stone shall be laid and firmly bedded into the slope and against adjoining stones. The stones shall be
laid with their longitudinal axes at right angles to the slope and with staggered joints. The stones shall be well rammed into the bank or surface to
be protected and the spaces between the larger stones shall be filled with spalls of approved pitching stone securely rammed into place.
Method 2
The technique and requirements laid down in Method 1 shall also apply to Method 2, except in the following aspects:
• No small stones or spalls shall be used to fill in spaces between larger stones.
• Simultaneously with the placing of stones, topsoil shall be introduced between individual stones, and sufficiently rammed so as to provide a
firm bonded structure. The topsoil shall be provided to the full depth of the stone pitching at any point
• Rooted grass or tufts of grass shall then be planted in the topsoil between stones and watered immediately and copiously and thereafter at
regular Intervals until grass has been established.
Whichever of the above two methods is adopted, the finished surface of the pitching shall present an even, tight and neat appearance with no
stones varying by more than 25 mm from the specified surface grades or lines. The thickness of the pitching, measured at right angles to the
surface, shall not be less than 200 mm.
b) Grouted stone pitching with mortar
Grouted stone pitching shall be constructed in terms of Clause A3.3.7.1i)(i) in Chapter 3.
c) Grouted stone pitching on a concrete bed
Grouted stone pitching on a concrete bed shall be constructed in terms of Clause A3.3.7.1i)(ii) in Chapter 3.
A11.1.7.3 Riprap
a) General
Riprap shall consist of a course or courses of large rock placed on bank slopes and toes in stream and riverbeds and at other localities where
protection of this type may be required.
Two types of riprap are specified here, viz one type where the rocks are individually packed, which is designated as packed riprap, and the other
type where the rock is dumped and then spread by machines, which is designated as dumped riprap.
The surface of areas to receive riprap shall be neatly trimmed to line and level and all loose material compacted. The perimeters of riprap areas
shall be protected by the construction of either rock-filled trenches, walls or other structures as may be required. Perimeter trenches shall normally
be backfilled with rock of the same size and quality as that used in the construction of the adjoining riprap, but any voids shall be filled with smaller
stone and the entire backfill shall be well compacted.

b) Filter bed
The filter bed shall consist of a layer or layers of permeable material placed on the prepared surface to the required thickness and each layer shall
be finished to an even surface and thickness. Compaction of pervious material will not be required. Care shall be taken not to mix various grades
of filter material neither to disturb material already placed when subsequent layers or riprap are being placed.
When the use of geotextile is required, the geotextile shall be placed on the prepared surface or on the filter bed, depending on the Instructions.
The overlap between adjacent sheets shall be 150 mm unless otherwise specified. Care shall be taken not to damage the geotextile when
subsequent layers are being placed, neither to expose the geotextile to the sun for periods exceeding 3 days before it is covered up.
c) Packed riprap
Packed riprap shall be constructed with rocks placed individually to stagger the joints and so as to be firmly bedded in the prepared surface. The
spaces between larger stones shall be filled with spalls or smaller stones securely rammed into place. On inclined surfaces the rock shall be laid
in long horizontal strips starting from the bottom, and not in strips up the slope.
The completed riprap shall present a tight and even surface. Local surface irregularities of the riprap shall not exceed 150 mm.
d) Dumped riprap
Dumped riprap shall be constructed by dumping the stone on the prepared surface, spreading it by bulldozer, or other suitable earth-moving
equipment, and trimming it to the required lines and levels. The material shall be placed in a manner that will prevent the segregation of the smaller
and larger stones and the top layer shall be tight with a minimum of voids.
A11.1.7.4 Stone masonry walls

a) General
Stone masonry walls may be plain packed stone walls with mortared stone walls with stones bedded in cement mortar as specified and indicated
on the drawings.
b) Plain packed stone walls
A foundation trench shall be excavated down to rock, or to material with an adequate bearing capacity at a minimum depth of 300 mm below ground
level or as indicated on the drawings. Large selected stones shall be used for the foundation layer. Thereafter flat and stratified stones shall be laid
with the largest dimension in the horizontal plane. Stones shall be packed individually to stagger the joints and to provide a minimum of voids, and
shall be firmly bedded against adjoining stones. The spaces between the larger stones shall be filled with spalls securely rammed into place. The
larger stones shall not bear on the spalls used for filling the voids. The top and ends of the wall shall be neatly finished with selected coping stones.
The appearance of the completed wall shall present an even, tight surface.
c) Cement-mortared stone walls
The foundation and walling shall be constructed as specified for plain packed walls in Clause A11.1.7.4b), with the exception that the stones,
including the foundation layer, shall be wetted and set in a mortar bed. The exposed parts of the stones on the wall faces shall be cleaned of all
mortar by washing or wire-brushing. The mortar shall be flush pointed to the specification of the Engineer, who may require a capping and end
treatment of the same mortar.
Weep holes shall be provided as prescribed and shall be cleaned of mortar or any other clogging material that may have entered during construction.
The walling shall be protected from the elements and kept moist for a minimum period of four days after completion.
A11.1.7.5 Concrete pitching

a) General
The underlying layers for surfaces to be pitched shall be constructed as specified or as indicated on the drawings. Where no specified requirements
have been set in respect of the underlying layers, the top layer shall be mechanically compacted to at least 93 % of MDD down to at least 150 mm
from the top. During this process the top layer shall be trimmed to the required grades and levels.
Where specified by the Engineer the prepared surface shall be treated with approved environmentally friendly herbicide and ant poison before the
layer of sand for bedding is placed.
b) Edge beams
Concrete edge beams or any such other edge supports shall be constructed onto the supporting layer in accordance with the details shown on the
drawings and shall be constructed and left to cure before any paving blocks are laid.
c) Concrete grass blocks
Concrete grass blocks of the size specified or shown on the drawings shall be placed on areas prepared for grassing as specified in Section A11.8.
The holes in the blocks shall be filled with topsoil and grassed with grass cuttings or hydroseeding as specified in Section A11.8.
A11.1.7.6 Cast in situ concrete pitching

The areas where cast in situ concrete pitching is to be constructed shall be compacted, trimmed and prepared as described in Clause A11.1.7.5a).
The areas shall also be treated with vegetation destroyer and ant poison if required.
Prior to placing the concrete, the surface shall be watered and kept damp until the concrete has been placed. Where specified, steel reinforcing of
the type specified shall be placed at the required location and depth. Unless otherwise specified, class C20/25-20 concrete shall be used, and the
concrete shall be accurately laid in alternate panels to the lines and levels indicated, after which the remaining panels shall be similarly placed.
Accurately set-up guides shall be used to achieve the required line and slope. The concrete shall be thoroughly compacted and finished to a class
U2 surface finish.

Where indicated, the concrete pitching shall be contained by concrete edge beams being constructed as described in Clause A11.1.7.5b).
The concrete pitching shall be cured for at least seven days and no traffic shall be allowed to move across the surface before the specified 28-day
strength has been reached.
The final surface may nowhere deviate by more than 25 mm from the specified levels and planes, and no irregularities exceeding 10 mm may
occur during testing with a 3,0 m straightedge.
A11.1.8 WORKMANSHIP
A11.1.8.1 General
The Engineer may, at his discretion, decide to use the Contractor’s test results if he is satisfied that the Contractor has complied with the process
control requirements.
with the requirements or, if the Engineer so permits, shall be repaired so that it shall comply with the specified requirements after having been
repaired.
A11.1.8.2 Finishing requirements: Grass-block pavement

The completed grass-block pavement shall have a neat and even appearance. The final surface of the pavement may not deviate by more than 15
mm from the specified levels and planes over the entire surface.

B11.1 PITCHING, STONEWORK, CAST IN SITU CONCRETE FOR
CONTENTS
B11.1.1 SCOPE
B11.1.2 DEFINITIONS
B11.1.3 GENERAL
B11.1.5 MATERIALS
B11.1.8 WORKMANSHIP
B11.1.1 SCOPE
This Section covers the furnishing of materials and the construction of protective coverings using stone, cast in situ concrete, bricks or prefabricated
concrete blocks on exposed surfaces such as earth slopes, drains and stream beds, as well as heavier protective layers in the form of riprap and
the construction of stone masonry for walls, as specified and shown on the drawings, or as specified by the Engineer
This Section therefore includes work with a large component of labour.
This Part B therefore only covers additional specifications for work to enhance the labour component of construction activities where specified in
Part A. This Section includes concrete mixed by hand.
B11.1.2 DEFINITIONS
B11.1.3 GENERAL

B11.1.5 MATERIALS
When packed riprap is constructed using labour enhanced construction methods, the stone for the riprap shall have a maximum size of 0,03 m3 or
a maximum mass of 30 kg.
B11.1.5.2 Concrete
a) Concrete mixing by hand
Concrete may be mixed by hand or in hand-turned concrete mixers for small pours up to one (1) cubic metre. Larger pours greater than one cubic
metre shall be machine mixed with on-site mechanical mixers and/or batch plants.
strength so that, considering the expected variability of the concrete and test procedures, no more than 5 % of strength tests will be expected to
fall below the specified characteristic compressive strength.


B11.1.7.1 Classification of excavation
intermediate for payment purposes in terms of Table B11.1.7-1 or, if the Contractor does not agree with the classification, in terms of Table B11.1.7-
2. The decision of the Engineer regarding the classification of the excavated materials shall then be final and binding, subject to the provisions of
the conditions of contract.
Materials
Description
Classification
Soft
hand-swung tool.
Intermediate

Materials
Classification

If specified, concrete shall be transported by wheelbarrows up to a maximum haul distance of 50 m. When the haulage exceeds 50 m, the concrete
shall be transported by dumper or other means for the full distance.
B11.1.8 WORKMANSHIP

C11.1 PITCHING, STONEWORK, CAST IN SITU CONCRETE FOR
(i) Preamble
3. No separate payment will be made for the protection or repair as required of any existing or new road furniture, infrastructure or services
damaged by the Contractor’s activities.
pay items.
km.
specifications.
Clearing and grubbing and removal of trees A11.1.7.1
applicable items
Loading and hauling A11.1
applicable items


C11.1.1 Foundation trenches for stone masonry walls
C11.1.1.1 Excavating foundation trenches in soft material using labour enhanced construction methods cubic metre (m3)
0 m to 1,0 m depth
C11.1.1.2 Excavating foundation trenches in intermediate material using labour enhanced construction cubic metre (m3)
methods 0 m to 1,0 m depth
The unit of measurement shall be the cubic metre of material excavated for foundation trenches in accordance with the authorised dimensions,
measured in place before excavation.
Excavations shall be done using labour enhanced construction methods as specified and measured.
The tendered rates shall include full compensation for the excavation of the foundation trenches to the required dimensions, lines, levels and
grades, the trimming of the open drain and the loading and disposal of the material as directed.
Loading and hauling, where applicable, including a haul of 1,0 km, shall be measured and paid as specified in Section C1.7 of Chapter 1. Where
the excavation of material is specified by means of labour enhanced construction methods, the tendered rates shall include loading and transport
by wheelbarrow if the material is disposed of or utilised within a radius of 50 m, alternatively loading by hand onto transport vehicles for such
disposal or utilisation elsewhere, within a haul distance of 1,0 km.
C11.1.2 Stone pitching
C11.1.2.1 Plain stone pitching
(a) Method 1 square metre (m²)
(b) Method 2 square metre (m²)
C11.1.2.2 Grouted stone pitching with mortar square metre (m²)
C11.1.2.3 Grouted stone pitching on a concrete bed square metre (m²)

The unit of measurement for pitching shall be the square metre of each type of pitching in place.
The tendered rate for each type of stone pitching shall include full compensation for furnishing all materials, making all excavations excluding trench
and bulk excavations, compacting and trimming the excavated surfaces, forming the joints, placing stones and grouting, or wiring and grouting
where applicable grassing and watering (applicable to Method 2) and for all other work necessary for completing the pitching as specified. The
tendered rate for grouted stone pitching on a concrete bed shall also include full compensation for the concrete bed.
The tendered rates shall also include full compensation for mixing and/or procuring concrete, mortar and grout as indicated.
Excavations for foundation trenches and concrete edge beams and the construction of the concrete edge beams will be paid for separately.
C11.1.3 Riprap
C11.1.3.1 Packed riprap (“critical mass of stone” and thickness indicated) cubic metre (m3)
C11.1.3.2 Extra over item C1 1. 1. 3. 1 for constructing packed riprap using labour enhanced cubic metre (m3)
construction methods (Maximum size of stone shall be 0,03 m3 or a maximum mass of 30
kg)
C11.1.3.3 Dumped riprap (critical mass of stone and thickness indicated) cubic metre (m3)
C11.1.3.4 Filter layer consisting of:
(a) Crushed stone cubic metre (m3)
(b) Filter sand cubic metre (m3)
(c) Geotextile (type, class and grade stated) square metre (m2)
The tender rate for item C11.1.3.4(a) and (b) will be as specified in Clause A3.1.5.2b) of Chapter 3 and A11.1.7.2b).
The unit of measurement for riprap and filter layer shall be the cubic metre of riprap or filter layer in place and shall include rock used in trench
backfill. The unit of measurement for item C11.1.3.4(c) shall be the square metre of geotextile laid as specified, including overlaps.
Item C11.1.3.2 is an extra over item which will be paid if instructed to construct packed riprap using labour enhanced construction methods.
The rates tendered shall include full compensation for preparing the surfaces, including excavation (but excluding excavation for trenches and bulk
excavations) and for the furnishing, transporting, handling and placing of riprap or filter layers. The rate tendered for item C11.1.3.4(c) shall include

full compensation for procuring and furnishing the geotextile and for laying it as specified, including wastage. Collectively the rates shall also include
full compensation for all other incidentals necessary for completing the work as specified.
Excavations for foundation trenches and bulk excavation will be paid for separately.
C11.1.4 Stone masonry walls:
C11.1.4.1 Plain packed stone walls cubic metre (m3)
C11.1.4.2 Cement-mortared stone walls cubic metre (m3)
C11.1.4.3 Extra over items C11.1.4.1 and C11.1.4.2 for procuring stone from commercial sources cubic metre (m3)
The unit of measurement for stone masonry walls shall be the cubic metre of actual walling constructed and accepted.
The tendered rate for each type of stonewall shall include full compensation for furnishing all materials, trimming the areas, placing the stones and
cement-mortared masonry where necessary, and all other work necessary for completing the walls in accordance with the specifications.
Excavation of foundation trenches and bulk excavations will be paid for separately.
The tendered rate for item C11.1.4.3 shall include full compensation for procuring, furnishing and offloading stone from commercial
suppliers, including the cost of transporting the material to the site irrespective of haul distance.
C11.1.5 Concrete pitching or paving
C11.1.5.1 Cast in situ concrete pitching or paving (class of concrete and thickness of pitching or paving square metre (m2)
indicated)
C11.1.5.2 Prefabricated concrete grass blocks (type and thickness indicated) square metre (m2)
C11.1.5.3 Welded steel fabric used for cast in situ pitching or paving (type indicated) kilogram (kg)
The unit of measurement shall be the square metre of each type constructed.
The tendered rates shall include full compensation for furnishing all materials, all excavation (but excluding bulk excavation and excavation for
foundation trenches and edge beams), compacting and trimming all the excavated areas, treating the prepared surface with an approved herbicide
and ant-poison, laying concrete grass blocks (item C11.1.5.2), topsoiling and grassing, (item C11.1.5.2), constructing concrete pitching or paving,
including normal formwork and the shaping of surfaces (item C11.1.5.1), making and cleaning weepholes (item C11.1.5.1) and for all other work
necessary for completing the work as specified.
Welded steel fabric used for cast in situ pitching or paving shall be as specified in Section A13.3 of Chapter 13.
C11.1.6 Concrete edge beams (class of concrete indicated) cubic metre (m3)
The unit of measurement shall be the cubic metre of concrete in edge beams constructed as specified.
The tendered rate shall include full compensation for furnishing all materials and labour, including formwork as necessary, placing concrete and
shaping all surfaces and all excavations required. Where excavations cannot be efficiently done by labour then machinery can be employed.
The tendered rates shall also include full compensation for mixing and/or procuring concrete as indicated.
C11.1.7 Provision of approved herbicide and ant poison:
C11.1.7.1 Provision of materials Prime cost sum
C11.1.7.2 Contractor’s charges and profit added to the prime cost sum percent (%)
Payment under the prime cost sum for providing ant poison and herbicide and the Contractor's costs and profit, in this respect, shall be made in
accordance with the provisions of the general conditions of contract, but, in addition, the Contractor's tendered rate for costs and profit shall Include
compensation for applying the chemicals as specified.

D11.1 PITCHING, STONEWORK, CAST IN SITU CONCRETE FOR
CONTENTS
D11.1.1 SCOPE
D11.1.2 GENERAL

11.2 NON-STRUCTURAL GABIONS
CONTENTS
A11.2.1 SCOPE
A11.2.2 DEFINITIONS
A11.2.3 GENERAL
A11.2.5 MATERIALS
A11.2.7 EXECUTION OF WORKS
A11.2.8 WORKMANSHIP

A11.2 NON-STRUCTURAL GABIONS

A11.2.1 SCOPE
This Section covers the construction of non-structural gabion boxes and mattresses for constructing lining channels, revetments and other anti-
erosion and containment structures. For structural gabion work refer to Section A12.6 of Chapter 12.
A11.2.2 DEFINITIONS
A11.2.3 GENERAL
None applicable.

Structural retaining walls specifically designed for particular applications are specified in Section A12.6 of Chapter 12.
A11.2.5 MATERIALS
The required material specifications are for the materials as placed and/or processed in its final position within the road reserve.
It is the Contractor’s responsibility to ensure that the materials delivered shall meet the specified requirements as per Clause A12.6.5 of Chapter
12.
A11.2.5.2 Materials
a) Rock
As per Clause A12.6.5.2 of Chapter 12.
b) Wire

c) PVC-coated wire
d) Galvanizing
e) Wire mesh
f) Geotextile behind and below the gabions
g) Alternative materials

The Contractor shall submit his plant and equipment list for excavating, stockpiling if specified, loading and hauling as part of his method statement.

A11.2.7.1 Classification of materials
All excavations for gabion boxes and mattresses shall be excavated in the position and to the required dimensions. Overbreak in width or depth,
unless specified by the Engineer, shall be in filled by the Contractor and shall not be measurable for payment.
All excavations under this Section shall be classified as specified under Clause A11.1.7.1.
A11.2.7.2 Constructing gabion boxes and mattresses

a) General
Gabion boxes shall be manufactured from steel wire coated with zinc, zinc aluminium alloy double twisted wire mesh of the size and type and
selvedge as specified in Section A12.6 of Chapter 12. The boxes will be of two types and shall be subdivided into cells by wire mesh diaphragms.
Mattresses which are generally used as single-layer aprons in revetments, channel linings, etc, which the maximum width of units shall be 2,0 m,
and the maximum depth 0,3 m. Mattresses shall be subdivided by diaphragms into cells with a width of 1000 mm. Mattress shall be installed with
diaphragm spaced at 1,0 m in the direction of the flow, unless otherwise specified by the Engineer.
For the standard size for gabion boxes and mattresses refer to Section A12.6 of Chapter 12.
b) Selvedges
The cut edges of all mesh used in the construction of gabions, except the bottom edges of diaphragms and end panels, shall be selvedged with
wire with a diameter as specified in SANS 1580.
Where the selvedge is not woven integrally with the mesh but has to be tied to the cut ends of the mesh, it shall be attached by tying the cut ends
of the mesh to the selvedge, so that a force of more than 8,5kN applied on the selvedge in the same plane as the mesh of a mesh sample of 1,0
m in length will be required to separate it from the mesh.
c) Diaphragms and end-panels
The diaphragms and end-panels shall be selvedged on the top and vertical sides only. The end-panels shall be attached by the cut ends of the
mesh wires at the bottom of the panel being twisted around the selvedge on the base of the gabion. Similarly, the diaphragms shall be attached by
the cut ends of the mesh being twisted to the twisted joints of the mesh in the base of the gabion. In each case the force required to separate the
panels from the base shall not be less than 6kN/m.
d) Binding and connecting wire
Sufficient binding and connecting wire for all the tying to be done during construction of the gabions as specified in A11.2.7.2 shall be supplied with
the gabion boxes. The binding wire shall have the same properties as the gabion or mattress mesh wire.
e) Preparing the foundation and surface
The foundation surface on which the gabion boxes and mattresses are to be installed prior to their being filled with rock shall be levelled to the line
and level shown on the drawings or as directed by the Engineer so as to present an even surface. If necessary, cavities between rock protrusions
shall be filled with material similar to that specified in Clause A12.6.5.2b) of Chapter 12. Where required, a foundation trench along the toe of the
revetment or wall shall be excavated to the dimensions specified and/or shown on the drawings.
f) Geotextile
One layer of geotextile shall be placed where indicated on the drawings or as specified. The geotextile shall be placed, in strips with a minimum
overlap of 300 mm at the joints, and shall be properly fastened to prevent any movement or slipping while the gabions are being placed. Geotextiles
shall comply with the requirements as specified in Section A12.11 of Chapter 12.

g) Assembly
The methods of constructing, stretching, placing in position, wiring and filling the gabions with rock shall generally be in accordance with the
manufacturer's instructions subject to the approval of the Engineer, but nevertheless sufficient connecting wires shall be tensioned between the
vertical sides of all the outer visible cells and a sturdy frame shall be used to prevent the deformation of boxes as they are being filled with stone.
Joints between boxes shall be wired together along all 4 joining edges.
It is essential that the corners of gabion boxes be securely wired together to provide a uniform surface and ensure that the structure does not
resemble a series of blocks or panels. The layout and the tolerances for the layout of the boxes shall be as shown on the drawings or as specified
h) Rock filling
(i) Boxes in gabions
Particular care shall be taken in packing the visible faces of gabion boxes, where only selected stone of the specified size shall be
used so as to obtain an even-faced finish. The boxes shall be filled in layers to prevent deformation and bulging. Boxes shall be wire
braced and filled to just below the level of the internal wire braces, after which the braces shall be twisted to provide tension. Care
must be taken to ensure that consecutive layers of boxes are filled evenly to a level surface ready to receive the next course.
Filling of gabion boxes by dumping rock shall not be permitted and packing shall be done by means of hand labour.
(ii) Mattresses used in revetments and aprons
The 0,17 m, 0,23 m and 0,3 m mattresses forming aprons and revetments shall be filled by random stones being packed in the first
layer and by selected stones being used for the top layer so as to resemble normal stone pitching.
A11.2.8 WORKMANSHIP
A11.2.8.1 General
order to ensure that the quality of materials produced meets the specified requirements for the particular layer for which it will be used. Similarly,
the Contractor shall conduct sufficient checks and controls during construction of the elements to ensure that the required lines, levels and finishes
are achieved.
The Engineer may, at his discretion, decide to use the Contractor’s test results if he is satisfied that the Contractor has complied with the process
repaired.
A11.2.8.2 Tolerances
Tolerances for gabion and mattress materials and dimensions shall conform to the requirements of EN 10223-3.

B11.2 NON-STRUCTURAL GABIONS
CONTENTS
B11.2.1 SCOPE
B11.2.2 DEFINITIONS
B11.2.3 GENERAL
B11.2.5 MATERIALS

B11.2.8 WORKMANSHIP
B11.2.1 SCOPE
This Section covers the furnishing of materials and the construction of gabion aprons for constructing minor non-structural retaining walls, lining
channels, revetments and other anti-erosion and containment structures.
The construction of gabion boxes and mattresses shall be deemed to be a labour enhanced construction process.
Part A.
B11.2.2 DEFINITIONS
B11.2.3 GENERAL

B11.2.5 MATERIALS


All excavations under this Section shall be classified as specified under Clause B11.1.7.1.
B11.2.8 WORKMANSHIP

C11.2 NON-STRUCTURAL GABIONS
(i) Preamble
pay items.
km.
specifications.
applicable items


C11.2.1 Foundation trench excavation:
C11.2.1.2 Extra over sub-item C11.2.1.1 for excavation in hard material, irrespective of depth cubic metre (m3)
C11.2.1.3 Excavating soft material within 1,5 m below the surface level using labour enhanced cubic metre (m3)
construction methods:
C11.2.1.4 Excavating intermediate material within 1,5 m below the surface level using labour cubic metre (m3)
enhanced construction methods:
The tendered rates shall include full compensation for the excavation of the material to the required dimensions, lines, levels and grades, temporary
timbering, shoring and strutting, including unavoidable overbreak, the trimming of the trenches and compacting the trench inverts, backfilling of
over excavation and compacting the backfill, keeping excavations safe, dealing with any surface or subsurface water and the loading and disposal
of the excess material as directed. The tendered rates shall also include full compensation for any other operations necessary for completing the
work as specified, but excluding surface preparation for bedding the gabions.
Loading and hauling, where applicable, including a haul of 1,0 km, shall be measured and paid as specified in Section C1.7 of Chapter 1. Where
the excavation of material is specified by means of labour enhanced construction methods, the tendered rates shall include loading and transport
by wheelbarrow if the material is disposed of or utilised within a radius of 50 m, alternatively loading by hand onto transport vehicles for such
disposal or utilisation elsewhere, within a haul distance of 1,0 km.
For payment purposes a distinction shall be made between materials as classified above under Classification of Materials.
C11.2.2 Surface preparation for bedding the gabion boxes and mattresses square metre (m2)
The unit of measurement for levelling and preparing surfaces for receiving the gabion boxes and mattresses shall be the square metre to the neat
dimensions of revetments, aprons or wall foundations.
The tendered rate shall include full compensation for excavating, filling any cavities with rock, and levelling the ground surface so as to be ready
for receiving the gabion boxes tor retaining walls, aprons and revetments.
C11.2.3 Gabion boxes and mattresses:
C11.2.3.1 Galvanized gabion boxes (dimensions of box) cubic metre (m3)
C11.2.3.2 PVC coated gabion boxes (dimensions of box) cubic metre (m3)
C11.2.3.3 Galvanized gabion mattresses (dimensions of mattress) cubic metre (m3)
C11.2.3.4 PVC-coated gabion mattresses (dimensions of mattress) cubic metre (m3)

The unit of measurement shall be the cubic metre of the rock-filled boxes or mattresses and the quantity shall be calculated from the dimensions
of the gabions indicated on the drawings irrespective of any accepted deformation or bulging of the completed gabions. Gabions boxes and
mattresses shall be measured to the nearest specified size.
The tendered rates shall include full compensation for supplying all the materials, including rock fill, wire-mesh boxes, galvanizing, PVC-coating,
tying and connecting wires, loading, transporting and off-loading, the assembling and filling of the boxes, disposal of waste, and any other work
necessary for constructing the gabions. It shall exclude any geotextile fabrics which, if required, shall be measured and paid for under item C11.2.4.
Placing of rock by dumping shall not be allowed and the tendered rates shall also include full compensation for placing rock by means of hand
labour.

C11.2.4 Geotextile (type and grade indicated) square metre (m2)

The unit of measurement shall be the square metre of area covered with geotextiles placed in position as specified in Section A12.11 of Chapter
12.
The tendered rate shall include full compensation for supplying the geotextiles, cutting, waste, placing, joining, overlapping, and securing the
material in position.

D11.2 NON-STRUCTURAL GABIONS
CONTENTS
D11.2.1 SCOPE
D11.2.2 GENERAL

11.3 GUIDE BLOCKS AND KILOMETRE MARKERS
CONTENTS
A11.3.1 SCOPE
A11.3.2 DEFINITIONS
A11.3.3 GENERAL
A11.3.5 MATERIALS
A11.3.8 WORKMANSHIP

A11.3 GUIDE BLOCKS AND KILOMETRE MARKERS

A11.3.1 SCOPE
This Section covers guide blocks and other posts of precast concrete construction. Guiding demarcations or kilometre posts not of concrete
construction shall be specified and included under Section A11.6.
Guide blocks are located on the outer extremities of particularly narrow width roads to assist and guide road users in demarcating the road edge.
Kilometre markers are located at full or partial kilometre positions to demarcate the distance and route numbering. This Section covers the
manufacturing, supply and erection of guide blocks and markers, mainly constructed of precast concrete, in positions and in accordance with the
dimensions specified and/or shown on the drawings. Other precast elements may also be included under this Section, as specified under the
A11.3.2 DEFINITIONS
A11.3.3 GENERAL
No general items.

Not applicable.
A11.3.5 MATERIALS
The material specifications are the required specifications for the materials and guide blocks as manufactured placed and/or processed in their
final position within the road reserve.
It is the Contractor’s responsibility to ensure that the elements constructed and materials delivered to the road shall meet these specified
requirements.
A11.3.5.2 Concrete
All concrete work shall be carried out as precast elements in accordance with the requirements of Section A13.4 of Chapter 13. Unless otherwise
specified, a mixture of four parts of concrete sand or grit to one part of cement (Cem II 32.5) shall be used.
A11.3.5.3 Sand and grit

Sand and grit shall comply to the specifications in Clause A13.4.5.2 of Chapter 13. Grit shall comply to the aggregate grading as specified in Table
A9.1.5-5 of Chapter 9.
A11.3.5.4 Paint
Paint for guide blocks shall be non-reflectorised roadmarking paint as specified in Section A11.7. Paint for the recess in the block shall be retro-
reflective solvent or water-based paint as specified in Section A11.7. Unless otherwise specified, paint for the block shall be of white colour.

Alternative materials for posts, foundations or markers may be specified in the Contract Documentation.

The Contractor shall submit his plant and equipment list for manufacturing as part of his method statement to perform the different elements of the
Works.

All excavations for guide blocks and kilometre markers shall be excavated in the position and to the required dimensions. Overbreak in width or
depth, unless specified by the Engineer, shall be in filled by the Contractor and shall not be measurable for payment.
A11.3.7.2 Fabricating
Precast units shall be fabricated to the dimensions specified and/or shown on the drawings. The forms shall be smooth and shall have accurate
dimensions. The concrete mixture shall be placed in the forms and vibrated on a vibrating table or by other approved means. The units shall be
reinforced as shown on the drawings and shall have an F3 surface finish.
The units shall be true to shape, smooth, and without any honeycombing or other blemishes. After curing of the concrete, the recess near the top
of the unit shall be painted with the reflective paint specified, while the remainder of the top half of the unit shall be painted with road marking paint
of the specified colour.
A11.3.7.3 Spacing the guide blocks and kilometre markers

The guide blocks and kilometre markers shall be spaced and located as specified and/or shown on the drawings.
A11.3.7.4 Erecting
Guide blocks shall be erected after the surfacing has been completed.
Holes shall be excavated in the shoulder of the road and the blocks placed vertically and square to the road centre line.
Kilometre markers shall be erected after the completion of all machine trimming at the positions indicated on the drawings or as specified by the
Engineer.
Backfilling shall be compacted in layers not exceeding 100 mm from the bottom of the hole. Surplus excavated material shall be disposed of by the
Contractor at no additional payment.
The units shall be painted prior to installation. Care shall be exercised not to damage or soil the exposed painted surfaces during transportation
and installation.
Guide blocks and kilometre markers shall be maintained and protected during the entire construction period and any units damaged or broken
before the seal has been completed, the road markings have been painted or the certificate of completion has been issued, shall be repaired or
replaced, as may be required, at the Contractor's cost.
A11.3.8 WORKMANSHIP
The Engineer may, at his discretion, elect to use the Contractor’s test results if he is satisfied that the Contractor has complied with the process

Any work or materials which do not comply with the specified requirements, shall be removed and replaced with work or materials which
comply with the requirements or, i f the Engineer so agrees, shall be repaired so that i t shall comply with the specified requirements after
having been repaired.

B11.3 GUIDE BLOCKS AND KILOMETRE MARKERS
CONTENTS
B11.3.1 SCOPE
B11.3.2 DEFINITIONS
B11.3.3 GENERAL
B11.3.5 MATERIALS

B11.3.8 WORKMANSHIP
B11.3.1 SCOPE
This Section covers the manufacturing, supply and erection of guide blocks and kilometre markers, mainly constructed of precast concrete, in
positions and in accordance with the dimensions specified and/or shown on the drawings.
Part A. This Section includes concrete mixed by hand.
B11.3.2 DEFINITIONS
B11.3.3 GENERAL

B11.3.5 MATERIALS
B11.3.5.2 Concrete
a) Concrete mixing by hand
strength so that, considering the expected variability of the concrete and test procedures, no more than 5 % of strength tests will be expected to fall
below the specified characteristic compressive strength.



B11.3.8 WORKMANSHIP

C11.3 GUIDE BLOCKS AND KILOMETRE MARKERS
(i) Preamble
1. Unless otherwise ordered or stated in the Contract Documentation, for excavations will be measured from the ground surface.
pay items.
km.
specifications.
Kilometre markers on posts C11.3.2/C11.3.3 C11.6.4

C11.3.1 Guide blocks number (No)
C11.3.2 Kilometre markers number (No)
C11.3.3 Kilometre markers mounted on concrete reinforced pipes (diameter to be specified) number (No)
The unit of measurement shall be the number of units supplied and erected in accordance with the specifications and detailed on the drawings.
Excluded from items C11.3.2 and C11.3.3 shall be kilometre markers on posts measured under item C11.6.4.
The tendered rate shall include full compensation for supplying all materials and labour, manufacturing and transporting the precast units, setting
out, excavating and backfilling all the holes and disposing of surplus excavated material placing and painting the guide blocks and kilometre markers
and all the equipment the tools and incidentals necessary for completing and maintaining the works described in this section. Where kilometre
markers are erected in concrete pipe units, the tendered rate shall include the provision and installation of such concrete pipes, as detailed on the
drawings.

D11.3 GUIDE BLOCKS AND KILOMETRE MARKERS
CONTENTS
D11.3.1 SCOPE
D11.3.2 GENERAL

11.4 ROAD RESTRAINT SYSTEMS
CONTENTS
A11.4.1 SCOPE
A11.4.2 DEFINITIONS
A11.4.3 GENERAL
A11.4.5 MATERIALS
A11.4.8 WORKMANSHIP

A11.4 ROAD RESTRAINT SYSTEMS

A11.4.1 SCOPE
This Section covers the supplying, installing and maintaining of various types of Road Restraint Systems (RRS) at locations and in accordance
with the specifications and details, dimensions and design shown on the drawings; or specified by the Engineer; or as specified by the performance
based system manufacturer. There are two types of Road Restraint Systems, namely Vehicle Restraint Systems (VRS) and Pedestrian Restraint
Systems (PRS), these systems may either be rigid, semi rigid or flexible, with transitions between the different types.
Vehicle Restraint Systems shall be divided into systems based either on:
1. Method specification timber post systems with elements conforming to SANS 1350 and other SANS compliant material requirements and
installation specifications; or concrete barrier systems detailed in the Contract Documentation; OR
2. Performance based systems where the installation shall conform to EN 1317 (Parts 1 to 8) and/or AASHTO MASH or NCHRP350 as
alternative where no MASH product is available.
The selection of use shall be based on the risk threshold as determined by the designer. Performance based systems criteria shall be specified in
the specifications and measurement and payment section and the Contractor shall be obligated to provide a system which is fully compliant.
Included are end wings, bullnoses, and bridge adaptors to SANS 1350; end treatments and transitions to rigid elements to specific project
requirements and indicated on the drawings or specified by the Engineer; and end treatments, crash cushions and transitions to rigid elements of
performance based specification compliant to EN1317 and/or AASHTO MASH.
Moveable vehicle restraint systems required for traffic accommodation during construction and truck mounted attenuators are specified in Clauses
A1.5.5.4, A1.5.5.7, A1.5.6.1 and A1.5.7.11 of Chapter 1.
A11.4.2 DEFINITIONS
Road Restraint Systems (RRS) – are primarily used to protect vehicle occupants from impacting road furniture or hazards and vehicles reaching
opposing carriageways. They are also intended to protect pedestrians, and any other entity using a roadway.
Vehicle Restraint Systems (VRS) – which include, but are not limited to:
• Longitudinal barriers
• Terminals and transitions
• Safety barriers
• Vehicle parapets
• Crash cushions
• Arrestor beds

Pedestrian Restraint Systems (PRS) – which include, but are not limited to:
• Pedestrian parapets
• Pedestrian guardrails
AASHTO MASH – American Association of State Highway and Transportation Officials and Manual for Assessing Safety Hardware
EN 1317 (Parts 1 to 8) – European Norm for Road Restraint Systems
• Part 1: Terminology and general criteria for test methods
• Part 2: Performance classes, impact test acceptance criteria and test methods for safety barriers
• Part 3: Performance classes, impact test acceptance criteria and test methods for crash cushions
• Part 4: Performance classes, impact test acceptance criteria and test methods for terminals and transitions
• Part 5: Product requirements and evaluation of conformity for vehicle restraint systems
• Part 6: Pedestrian Restraint Systems
• Part 7: Performance classes, impact test acceptance criteria and test methods for terminals of safety barriers
• Part 8: Motorcycle Road Restraint Systems
Containment levels – defines the ability of the RRS to restrain the design vehicle. A containment level is achieved by the system withstanding a
defined crash test influenced by the speed, the mass and impact angle of the vehicle which needs to be contained and redirected.
Normalised working width – is a measure of the deformation of a barrier under impact, i.e. the space needed behind the barrier in order for the
system to work properly. The working width is divided into 8 classes, W1 to W8 (EN 1317).
A11.4.3 GENERAL
Road Restraint Systems, for both temporary and permanent use, shall be sourced from a reputable manufacturer or supplier, being affiliated to a
recognised industry association, and installed by a competent installer, who is either certified by the manufacturer or supplier, or affiliated to a
recognised industry association.

Performance based vehicle restraint systems provided by the Contractor shall be required where specified on the drawings or Contract
Documentation, both as temporary and permanent applications, as specified for containment level and working width and shall conform to the
product class specification criteria and containment levels as per the latest version of EN 1317 or NCHRP350/MASH based on the risk profile
determined at the specific location(s) by the Engineer. Included into the Contractors submission shall be the requirements and procedures to
maintain EN 1317 and/or AASHTO MASH compliance in the event of repairs due to damage during the construction period and post construction.
The specific materials and construction requirements for repair and maintenance activities shall be provided to the Engineer together with the
manufactures’ specifications.
Where offered and accepted or specified to be used, steel posts or other steel elements being part of an approved vehicle restraint system as
tested and complying with EN 1317 and/or AASHTO MASH shall be galvanized in compliance with the requirements of SANS 121.
Where such vehicle restraint systems are placed on concrete retaining walls or concrete structures, the steel posts attachment to the concrete shall
be required to be an element of a system shall be specified as also complying with EN 1317.
A11.4.5 MATERIALS
It is the Contractor’s responsibility to ensure that the materials delivered to site shall meet these specified requirements.
The type of non-performance based guardrail systems installed will be selected based on the Employer’s maintenance strategy to ensure that the
systems selected do not impose an onerous maintenance burden on the Employer for post construction repair or replacement requirements.
A11.4.5.2 Materials
a) Steel guardrails for erection on timber posts
Steel guardrails shall comply with the requirements of SANS 1350 and carry the SABS mark or a mark by any other SANAS approved certification
body for the applicable SANS specification for 3,81 m length railings, as specified.
The dimensions of guardrails, end wings, bull noses and bridge adaptors shall be in accordance with the details indicated in the appropriate figures
defined in SANS 1350. The dimensions of end treatments and alternative bridge adaptors shall be in accordance with the details shown on the

drawings.
Steel guardrails shall be supplied together with all the bolts, nuts, washers and fixing materials required
Unless specified to the contrary in the Contract Documentation, all guardrails shall be galvanized with a hot-dip zinc coating, which complies with
the requirements of SANS 121.
All bolts, nuts and washers shall have a hot-dip zinc coating, which complies with the requirements of SANS 121.
Galvanized guardrails shall be stacked according to the manufactures specifications and not be nested directly on each other when stacked for
storage.
b) Concrete
All concrete work shall be carried out in accordance with the requirements of Section A13.4 of Chapter 13, read together with the provisions of
Clause A11.1.5.4.
c) Guardrail posts
(i) Timber posts

Timber posts and spacer blocks shall be supplied in lengths and dimensions as shown on the drawings and shall comply with the
requirements of SANS 457 part 2 or part 3.
Posts shall have a top diameter of not less than 150 mm. Posts with a top diameter up to 230 mm will be acceptable, provided that
posts with widely varying diameters shall not be used together in the same length of guardrail. The tops of poles shall either be
domed or bevelled to ensure rainwater is drained.
Posts shall be drilled and shaped as shown on the drawings and supplemented with the necessary bolts, nuts, washers and spacer
blocks for fixing.
Timber posts and spacer blocks shall be treated in accordance with SANS 10005 with creosote that complies with SANS 616, or if
it is approved by the Engineer it shall be treated with a copper-chrome-arsenic compound for timber preservation, which complies
with SANS 673. The preservative specified in the Contract Documentation shall be used. After the posts have been treated, they
shall not be sawn, drilled or shaped without being retreated with preservative in accordance to SANS 10005.
Timber Posts which, in accordance to the inspection methods detailed in SANS 457, exhibit a degree of cracking that would render
them unfit for service shall not be used.
(ii) Steel posts
Steel posts, where specified for special application purposes, shall meet the requirements indicated on the drawings and be
galvanized in compliance with SANS 121.
(iii) Steel base plates for timber posts
Where it is necessary to install timber guardrail posts on top of a culvert or other concrete structure, and/or where the total thickness
of the fill and pavement layers over such structure is less than 1,0m, the timber posts shall be fastened to the structure by means
of steel base plates as shown on the drawings.
d) Reflective plates
Reflective plates shall conform to the colour, layout and shape requirements of the SADC or South African Road and Traffic Signs Manual, to be
visible from both directions and constructed to bolt onto metal guardrails or alternative attachment to other vehicle restraint systems.
(i) Steel plates
Steel plates used for reflective plates shall be galvanized and painted to comply with the requirements of Clause A11.6.5.2c). The
complete reflective unit shall comprise a securely attached and firm unit proven to be vandal resistant, UV stabilised and impact
modified to ensure brittleness does not occur within the expected 7 year lifetime. Unless otherwise specified, the outer surfaces
shall be coated with class I white retro-reflective prismatic material and class III red retro-reflective material, which complies with
the provisions of SANS 1519-1.
(ii) Plastic plates
Plastic guardrail reflector housing shall be fabricated with a Carbon Black UV Resistant “Acrylonitrile Butadiene Styrene” (ABS) with
impact strength for moderate mechanical impacts. It should also have a 7 year lifespan with local outdoor conditions without
becoming brittle or cracking. The reflectors should be securely fixed to the guardrails at specified distances or as per the drawings.
Unless otherwise specified, the outer surfaces shall be coated with class I white retro-reflective prismatic material and class III red
retro-reflective material, which complies with the provisions of SANS 1519-1.
Specification certificates must be requested from the manufacturer.

The Contractor shall submit his plant and equipment list for excavating, stockpiling if specified, loading and hauling as part of his method statement
to perform the different elements of the Works.

All excavations for vehicle restraint systems shall be excavated in the position and to the required dimensions. Overbreak in width or depth, unless
specified by the Engineer, shall be in filled by the Contractor and shall not be measurable for payment.
A11.4.7.2 Construction of guardrails on timber posts

The holes for the guardrail timber posts shall be of sufficient size to permit the proper setting of the posts and to allow sufficient room for backfilling
the hole and tamping the filling. At least 1,0 m of a post shall be embedded in the ground.
The holes for the guardrail posts shall be spaced to suit the standard length of the guardrail supplied in accordance with SANS 1350, unless
otherwise specified by the Engineer or indicated on the drawings. Where shown on the drawings or indicated in the Contract Documentation, posts
shall be set at half or quarter the standard spacings.
The posts, spacer blocks (if applicable) and guardrails shall be completely erected and set true to line and level, so that the guardrails will be at
the required height above the level of the completed road shoulder. Where jointed, the end of the guardrails, which overlaps on the side of the
traffic, shall point in the direction of the traffic movement. The guardrail shall be suitably braced to prevent any movement, and all bolts shall be
tightened prior to any holes being backfilled. Steel posts where specified for use at specific locations, shall be installed as indicated on the drawings,
and shall be deemed to resort under this Clause A11.4.7.2
After the Engineer has signified his acceptance of the guardrail alignment so erected, the holes shall be backfilled with an approved sandy soil.
The material shall be mixed with the correct quantity of water to ensure that the mixture will be placed while at or near the optimum moisture
content. The mixture shall then be placed and thoroughly rammed in layers not exceeding 100mm of compacted thickness.
End treatments shall be constructed as shown on the drawings.
When the backfilling has been completed and the bracing removed, the posts shall be rigid and vertical, and the guardrail shall be true to line and
level and firmly fixed to the posts. Excess excavated material shall be disposed of by the Contractor at no additional payment.
Steel posts installed on concrete retaining walls or concrete structures as part of a timber supported guardrail section shall be erected and fixed as
All guardrails shall be so erected as to have no projecting ends, which might interfere with or endanger traffic, particularly during the installation
process. The edges and the centre of the guardrails shall touch either the spacer block or the post where no spacer blocks are used. Guardrails,
if specified, shall be provided with end units as shown on the drawings. All splices of guardrails shall be at posts, and guardrails shall make contact
over the entire area of the splice.
Reflective plates shall be fixed in accordance with the details shown on the drawings or in accordance with the manufacturers specifications. The
reflective surfaces shall be arranged with the colours facing the direction as shown on the drawings.
A11.4.7.3 Removing, renovating and r e-erecting existing guardrails on timber posts

Where existing guardrails have to be removed, or removed and re-erected, or removed, renovated and re-erected, the three processes of removal,
renovation and re-erection shall be carried out as follows:
a) Removing guardrails
All guardrails, reflective plates and end units shall be loosened. Posts shall be carefully dug out and the holes shall be filled and compacted in 100
mm layers of suitable material from site or commercial sources as indicated by the Engineer (minimum of G7 quality material). Items used for fixing,
such as bolts, nuts and washers, together with the reflective plates, shall be placed into bags, after which all the material shall be transported to a
store approved by the Engineer and all stored in groups by type.
Where material is intended for re-use, it shall first be unpacked for inspection by the Engineer for deciding which material will be suitable for re-
use. Suitable material shall then be stored separately from material, which is unsuitable for reuse. The Contractor shall dispose of material that is
unsuitable for reuse.
All guardrail holes shall be backfilled and material compacted in 100 mm layers to minimum of 93 % of MDD using material of at least G7 quality.
b) Renovating and painting guardrails
If so directed by the Engineer, guardrails and end treatments suitable for re-use shall be taken to a workshop for cleaning and painting. Renovated
guardrail dimensional tolerances shall comply with SANS 1350. Painting of guardrails shall be executed as specified in Clause A13.10.7.6 of
Chapter 13. Damaged guardrails should not be used or retrofitted. Re-rolling of guardrails shall not be permitted.
Timber posts suitable for re-use shall be cleaned and treated by applying a coating of creosote. Bolts, nuts and washers to be re-used shall be
cleaned and all rust removed, and shall then be oiled.
c) Re-erection
The guardrails shall be erected in the positions as indicated, and all the removed material suitable for re-use and as much supplementary new
material as may be necessary shall be used. Re-erection shall be as specified for new guardrails, including fixing the retro-reflective plates.
A11.4.7.4 Construction of concrete barrier systems

Non-performance based concrete barrier systems shall be constructed as specified in Section A13.8 of Chapter 13 and the Contract
Documentation.

A11.4.7.5 Construction of performance based vehicle restraint systems
Construction, installation and repair (if required) of performance based systems shall be in accordance with the manufacturers specifications, and
in compliance with EN 1317 or AASHTO MASH certification requirements, as relevant.
A11.4.8 WORKMANSHIP
The completed vehicle restraint system shall have a neat appearance and shall not show any visible deviations from line and grade. Posts shall be
straight and vertical. Longitudinal elements shall not be warped but shall be in a vertical plane parallel to the road centreline except at flared terminal
sections. The galvanized surface on the vehicle restraint systems shall be smooth and continuous and free from abrasions or scratches. Any
damage to the surface shall be repaired or replaced at the Contractor's expense. The methods of repair to the galvanized zinc coating shall be as
specified in SANS 121. Zinc rich paint systems applied with aerosol techniques shall not be permitted.
Vehicle restraint systems, which do not comply with the prescribed requirements, shall be replaced or otherwise repaired.
The Contractor shall avoid any damage to completed road sections, or the spillage of concrete on completed road surfaces. Any such damage or
spillage shall be rectified at the Contractors cost.
order to ensure that the quality of materials produced will meet the specified requirements for the particular use for which it is intended.

B11.4 ROAD RESTRAINT SYSTEMS
CONTENTS
B11.4.1 SCOPE
B11.4.2 DEFINITIONS
B11.4.3 GENERAL
B11.4.5 MATERIALS

B11.4.8 WORKMANSHIP
B11.4.1 SCOPE
This Section covers the supplying, installing and maintaining of Road Restraint Systems at locations and in accordance with the specifications and
details, dimensions and design shown on the drawings.
The construction of guardrails on timber posts shall be deemed to be a labour enhanced construction process.
Part A.
B11.4.2 DEFINITIONS
B11.4.3 GENERAL

B11.4.5 MATERIALS
B11.4.6 PLANT AND EQUIPMENT


B11.4.8 WORKMANSHIP

C11.4 ROAD RESTRAINT SYSTEMS
(i) Preamble
1. Unless otherwise ordered or stated in the Contract Documentation, excavation depths will be measured from the ground surface.
pay items.
km.
specifications.
applicable items
Concrete barriers (in situ and precast) C11.4.3.1/C11.4.3.2 C13.8.1.1 of Chapter 13
Painting guardrails, end wings and bullnoses C11.4.8.1 C13.10.1.3 of Chapter 13


C11.4.1 Erecting of guardrails at 3,81 m spacing
C11.4.1.1 Complete galvanized system compliant to SANS 1350:
(a) On timber posts (Drawing reference) metre (m)
(b) On steel posts used at specific locations (Drawing reference) metre (m)
(c) On concrete or other surfaces, with spacer blocks but without posts (Drawing reference) metre (m)
(d) Extra over C11.4.1.1(a) and C11.4.1.1(b) for excavating holes of posts using labour metre (m)
enhanced methods (soft and intermediate)
C11.4.1.2 Terminal sections for 3,81 guardrails comprising of:
(a) End wings to SANS 1350 number (No)
(b) Bullnoses to SANS 1350 number (No)
(c) Bridge adapters to SANS 1350 number (No)
(d) End treatments where single guardrail sections are specified (Drawing reference) number (No)
(e) End treatments where double guardrail sections are specified (Drawing reference) number (No)
(f) Bridge adaptors (including extra rails and posts) (Drawing reference) number (No)
(g) Extra over C11.4.1.2(d) and C11.4.1.2(e) for excavating holes for posts using labour enhanced number (No)
methods (soft and intermediate)
The unit of measurement for C11.4.1.1(a) (b) and (c) shall be the metre of new guardrail systems as erected, including curved guardrails but
excluding length of terminal sections. The use of steel posts shall be deemed relevant under this item.
The unit of measurement for item C11.4.1.1(d) shall be the metre of guardrail system erected with holes specified to be excavated using labour
enhanced methods, paid extra over items C11.4.1.1(a) and C11.4.1.1(b).
The unit of measurement for C11.4.1.2(a) to (f) shall be the number of complete new end treatments of each type installed.
The unit of measurement for C11.4.1(g) shall be the number of end treatments with holes excavated using labour enhanced methods of
construction, paid extra over items C11.4.1.2(d) and C11.4.1.2(e).
The tendered rates shall include full compensation for furnishing all materials and labour for erecting and galvanizing the guardrails, complete with
posts, spacer blocks, bolts, nuts, washers and reinforcing plates, and excavating holes in all classes of material, concrete, backfilling and removing
any surplus material. It shall also include full compensation for incidentals in respect of supplying and erecting guardrails, end treatments, and
turned down sections.
Reflective plates to guardrails and drilling and blasting of holes shall be paid for separately
The tendered rate of item C11.4.1.1(c) and C11.4.1.2(g) shall include full compensation for excavating the necessary holes using labour enhanced
construction methods where specified by the Engineer, and shall be paid as an extra over item.
C11.4.2 Performance based vehicle restraint systems

C11.4.2.1 Complete longitudinal barrier system to EN 1317 or AASHTO MASH or NCHRP350 as
alternative where no MASH product is available:
(a) Guardrail system (state criteria including containment level & working width) metre (m)
(b) Cable barrier system (state criteria including containment level & working width) metre (m)
(c) Concrete barrier system (state criteria including containment level & working width metre (m)
(d) Etc for other types, permanent and temporary metre (m)
C11.4.2.2 Terminal sections for the following to EN 1317 or AASHTO MASH or NCHRP350 as
alternative where no MASH product is available:
(a) End treatments (State criteria EN or MASH and containment level) number (No)
(b) Crash cushions (State criteria EN or MASH and containment level) number (No)

(c) Transitions (State criteria EN or MASH and containment level, etc.)) number (No)
(d) Other types (State criteria EN or MASH and containment level, etc.) number (No)
C11.4.2.3 Relocation of temporary systems (Type, EN or MASH, or NCHRP350 as alternative where no metre (m)
MASH product is available, containment level and working width indicated)
The unit of measurement for C11.4.2.1 shall be the metre of specified vehicle restraint system (complying with EN 1317) as fully erected, excluding
length of terminal sections but including curved guardrails.
The unit of measurement for C11.4.2.2 shall be the number of complete end treatments of each type fully supplied and installed compliant with
EN1317 or AASHTO MASH or NCHRP350 as alternative where no MASH product is available as relevant.
The tendered rate for item C11.4.2.3 shall be metre of temporary vehicle restraint system removed and relocated to a different position, regardless
of the distance relocated. The tendered rates shall include full compensation for furnishing all materials and labour for erecting or removing (where
applicable) and galvanizing the guardrails, complete with posts, spacer blocks, bolts, nuts, washers and reinforcing plates as may be required, and
excavating or making holes in all classes of material, concrete, backfilling and removing any surplus material. It shall also include full compensation
for incidentals in respect of supplying and erecting guardrails, end treatments, crash cushions, etc. as applicable.
Where end treatments are specified not to comply with EN 1317 or AASHTO MASH or NCHRP350 as alternative where no MASH product is
available, but as indicated on drawings or specified by the Engineer, measurement and payment shall be made under item C11.4.1.2 or C11.4.9.
Reflective plates and drilling and blasting of holes will be paid for separately.
Drilling and blasting will be paid for separately under item C11.4.11.
C11.4.3 Project specific concrete barrier systems
C11.4.3.1 In situ cast concrete barriers (reference to drawing) metre (m)
C11.4.3.2 Precast concrete barriers (reference to drawing) metre (m)
C11.4.3.3 Installation and removal of precast concrete barrier system (reference to drawing) number (No)
C11.4.3.4 Relocating or stacking precast barrier moved in excess of 1,0 km number (No)
The unit of measurement for items C11.4.3.1 and 2 shall be the metre of concrete balustrade constructed in place or precast in accordance with
the drawings and specifications in Section A13.8 of Chapter 13.
The unit of measurement for item C11.4.3.3 shall be the number precast units installed, initially and subsequently, and removed as instructed by
the Engineer, with installation and removal of precast units measured once only for any instructed location or position.
The tendered rate shall include full compensation for furnishing all materials and labour for installing and removal of precast units complete with
bolts, nuts, washers and reinforcing plates as may be required.
The unit of measurement for item C11.4.3.4 shall be the number of units moved in excess of 1,0 km, which each precast unit has been transported,
either for re-installation or for stacking.
Loading and hauling, where applicable, including a haul of 1,0 km, shall be measured and paid as specified in Section C1.7 of Chapter 1.
The tendered rate shall include full compensation for furnishing all materials labour equipment and transport required to relocate precast units of
all sizes for re-use or stacking, including all costs related to stacking the units.

C11.4.4 Extra over for horizontally curved guard rails
C11.4.4.1 Extra over C11.4.1 and C11.4.11 for horizontally curved guard rails factory bent to a radius metre (m)
of less than 45 m
C11.4.4.2 Extra over C11.4.2.1(a) for horizontally curved guard rails factory bent to a radius of less metre (m)
than 45 m
The unit of measurement shall be the metre of curved guardrail specified and erected and measured in place.
The tendered rate extra over the rates tendered for items C11.4.12 and C11.4.11 or C11.4.2.1(a) shall include full compensation for all incidentals
in respect of supplying and erecting curved guardrails of radius less than 45 m.
C11.4.5 Additional guardrail posts for 3,81 m systems:
C11.4.5.1 Timber number (No)
C11.4.5.2 Steel (drawing reference) number (No)

C11.4.5.3 Extra over C11.4.5.1 and C11.4.5.2 for excavating holes of posts using labour enhanced number (No)
methods
The unit of measurement for additional guardrail posts shall be the number erected over and above those erected in accordance with the normal
spacing shown on the drawings.
The unit of measurement for item C11.4.5.3 shall be the number of holes specified to be excavated using labour enhanced methods.
The tendered rates of items C11.4.5.1 and C11.4.5.2 shall include full compensation for supplying and installing additional posts complete as
specified, excavating the necessary holes, erecting the posts, and backfilling the holes.
The tendered rate of item C11.4.5.3 shall include full compensation for excavating the necessary holes using labour enhanced construction methods
and shall be paid as an extra over items C11.4.5.1 and C11.4.5.2.
Drilling and blasting will be paid for separately under item C11.4.11.
C11.4.6 Reflective plates
C11.4.6.1 Steel plates number (No)
C11.4.6.2 Plastic plates number (No)

The unit of measurement shall be the number of reflective plates, steel and/or plastic installed.
The tendered rate shall Include full compensation for supplying all materials and labour required for manufacturing, painting and fixing the reflective
plates as specified and as shown on the drawings.
C11.4.7 Removing existing guardrails: metre (m)

The unit of measurement shall be the metre of guardrail removed, and the length shall be measured between the terminals points of the sections
removed including the end treatments, but excluding the anchor blocks and anchor cables, if any, projecting beyond the end treatments.
The tendered rate shall include full compensation for the work as described in Clause A11.4.7.3a) including loading, transporting to any point on
the site, and off-loading and stacking the material, and disposing of material unsuitable for re-use.
The tendered rate shall also include full compensation for the backfilling of all guardrail holes using material from site or commercial sources of at
least G7 quality and compacting material to minimum of 93 % of MDD.

C11.4.8 Renovating guardrail material:
C11.4.8.1 Painting guardrails, end wings and bullnoses metre (m)
The unit of measurement for sub item C11.4.8.1 shall be the metre of single guardrail, whether straight or curved, or end units painted as specified,
the length of which shall be measured in accordance with the measurements of the guardrail elements after dismantling.
The unit of measurement for subitem C11.4.8.2 shall be the number of treated posts.
The tendered rates shall include full compensation for the work as specified in Clause A11.4.7.2b), surface preparation, applying all the coats of
paint, repairing any damaged surfaces, and all materials and construction plant necessary for completing the work including the loading,
transporting to and from the workshops, off- loading and storing of the material.

C11.4.9 Re-erection of guardrails with recovered or provided material:
C11.4.9.1 Single guardrail metre (m)
C11.4.9.2 Double guardrail metre (m)
C11.4.9.3 Extra over C11.4.9.1 and C11.4.9.2 for excavating holes of posts using labour enhanced metre (m)
methods
The unit of measurement of items C11.4.9.1 and C11.4.9.2 shall be the metre of single or double guardrail re-erected with used and/or new material
and measured between the points where they are joined to the end units.
The unit of measurement for item C11.4.9.3 shall be the metre of guardrail system erected with holes specified to be excavated using labour
enhanced methods.
The tendered rates of items C11.4.9.1 and C11.4.9.2 shall include full compensation for re-erecting the guardrails as specified in Clause
A11.4.7.3c), including the loading, transporting between any two points on the site and off-loading the material and providing new fixing material.
Payment shall be made separately for any new material required, including spacer blocks, but not for other fixing materials. Where sections are
made entirely from new material, payment therefore shall be made under the appropriate items for new guardrails.
The tendered rate of item C11.4.9.3 shall include full compensation for excavating the necessary holes using labour enhanced construction methods

and shall be paid as an extra over items C11.4.9.1 and C11.4.9.2.

C11.4.10 End treatments to existing guardrails with recovered or provided material:
C11.4.10.1 End wings number (No)
C11.4.10.2 Bullnoses number (No)
C11.4.10.3 Bridge adaptors number (No)
C11.4.10.4 End treatments with single guardrails number (No)
C11.4.10.5 End treatments with double guardrails number (No)
C11.4.10.6 Extra over C11.4.10.4 and C11.4.10.5 for excavating holes of posts using labour enhanced number (No)
methods (soft and intermediate)
The unit of measurement shall be the number of end treatments installed with recovered and, in part, new material.
The tendered rates shall include full compensation for installing the end treatments and for all excavation and backfill, providing all anchors, fixing
materials and anchor blocks but excluding costs for steel and timber materials.
Apart from anchors, anchor blocks and fixing materials, payment will be made separately for all new materials. End treatments made completely
from new materials shall be paid for in accordance with the appropriate rates for new end treatments.
The tendered rate of item C11.4.10.6 shall include full compensation for excavating the necessary holes using labour enhanced construction
methods and shall be paid as an extra over items C11.4.10.4 and C11.4.10.5 per number of end treatments
C11.4.11 New material required for the re-erection guardrails with recovered materials:
C11.4.11.1 Guardrails, 3,81 m compliant to SANS 1350 number (No)
C11.4.11.2 Timber posts compliant to SANS 457 number (No)
C11.4.11.3 Steel posts number (No)
C11.4.11.4 Reflective plates number (No)
C11.4.11.5 Spacer blocks compliant to SANS 457 number (No)
C11.4.11.6 Splice bolt complete with nut and washer compliant to SANS 1350 number (No)
C11.4.11.7 Post bolt complete with nut and washer compliant to SANS 1350 number (No)
C11.4.11.8 Reinforcing plates (reference to drawing) number (No)

The unit of measurement for subitem C11.4.11.1 shall be the metre of guardrail provided, measured in accordance with the measurements of the
loose guardrail.
The unit of measurement for subitems C11.4.11.2 to 8 shall be the number of new timber posts, steel posts, reflective plates, spacer blocks, splice
bolts, post bolts and reinforcing plates provided, respectively.
The tendered rates shall include full compensation for supplying the material as specified. Item C11.4.3 shall apply to horizontally curved guardrails
factory bent to a radius of less than 45 m.
C11.4.12 Extra over items C11.4.1 and C11.4.2 for drilling and blasting holes for guardrail posts number (No)
The unit of measurement shall be the number of holes drilled and blasted with explosives in hard material, which cannot be excavated except by
drilling and blasting, or with the use of pneumatic tools or mechanical breakers.
The tendered rate shall include full compensation for additional work including amongst others all drilling, explosives, materials, labour and
equipment and all Incidentals required for making holes in hard materials by means of drilling and blasting.
C11.4.13 Steel base plates for guardrail posts on structures number (No)
The unit of measurement is the number of steel base plates installed complete as shown on the drawings or directed by the Engineer.
The tendered rate shall Include full compensation for supplying all labour, materials, equipment and transport required for manufacturing,
galvanizing and installing the base plates complete with cement mortar pad, for cutting the guardrail post to the required length, drilling an additional

hole, treating the hole and butt face with creosote and fixing the post all as specified on the drawings
C11.4.14 Nailing of gang nail plates on top of timber guardrail posts number (No)
The unit of measurement shall be the number of gang-nail plates supplied and fixed as specified.
The tendered rate shall include full compensation for supplying all materials and labour and for fixing to the top of the sealed guardrail post.
C11.4.15 Disposal of existing guardrails

metre (m)
C11.4.15.1 Straight or curved longitudinal guardrails
metre (m)
C11.4.15.2 End treatments with single guardrails
metre (m)
C11.4.15.3 End treatments with double guardrails
The unit of measurement shall be the metre of guardrail section, regardless of condition, disposed of, and the length shall be measured between
the terminals points of the sections removed. Item C11.4.15.1 shall include end wings, bull noses and bridge adapters but exclude the end
treatments.
The tendered rate may be positive or negative as assessed by the Contractor. The tendered rate shall include full compensation for the removal
from site and disposal of the guardrails, poles, spacer blocks, bolts and nuts as scrap including loading, transporting and off-loading. A full record
of the destination of guardrails disposed of shall be provided to the Engineer for control purposes.
Removal of the guardrails shall be measured and paid under item C11.4.7.

D11.4 ROAD RESTRAINT SYSTEMS
CONTENTS
D11.4.1 SCOPE
D11.4.2 GENERAL
D11.4.1 SCOPE
Refer to Clause A11.4.1 for performance based systems which comply to the EN 1317 and/or AASHTO MASH or NCHRP350 as alternative where
no MASH product is available.
D11.4.2 GENERAL
Reflective sheeting suppliers for reflector plates shall supply an official test report as per the requirements of SANS 1519-1.

D11.4.3.1 Performance based Vehicle Restraint Systems
Suppliers of Performance Based Systems will be required to obtain, from the foreign testing facility where the product was tested, a Type Approval
Report and submit it to a SANAS accredited Certification Body for independent verification at the cost of the supplier. Once verified, the Certification
Body will conduct auditing of the product being manufactured, to ensure that it is the same product as described in the Type Approval Report,
which will verify the testing report provided to the Engineer.
The manufacturer of the RRS will be required to issue a limited material defects warranty for a period of not less than 12 months.
The entity that is tasked with the installation of the RRS system must be a certified installer and certify that the system has been installed in
accordance with the manufacturers installation guidelines in order to comply with the crash testing conditions.

It is a requirement that the installer and repairers of a performance based system issue a certificate of compliance every time the work has been
completed.

11.5 FENCING
CONTENTS
A11.5.1 SCOPE
A11.5.2 DEFINITIONS
A11.5.3 GENERAL
A11.5.5 MATERIALS
A11.5.8 WORKMANSHIP

A11.5 FENCING
A11.5.1 SCOPE
This Section covers the erecting of new fences and associated works, the repair or improvement of existing fences and moving of existing fences
where necessary along the boundaries of the road reserve and elsewhere as indicated on the drawings or as specified by the Engineer. Also
included shall be the erection of temporary fences as well as the removal and stacking of fencing where specified by the Engineer.
Except when otherwise specified or approved, new or temporary fences shall be erected before construction on a particular section of the road is
commenced with, before other properties are occupied for construction related work, or before temporary bypasses are opened to traffic. The
requirement to ensure the safety of road users and protection of property and other rights of the public against access over property lines by
vehicles, pedestrians and animals shall be enhanced by functional fences installed and maintained at the appropriate time and position.
A11.5.2 DEFINITIONS
No specific definitions are applicable.
A11.5.3 GENERAL
The Engineer and Employer shall identify and point out any cadastral beacons to the Contractor prior to any clearing or digging of holes is
undertaken for fencing purposes. Any disturbed or removed cadastral beacons shall only be replaced by a registered Land Surveyor. Cadastral
beacons shall be clearly demarcated to avoid disturbance.
A11.5.3.1 Protection of livestock and property

From the time of the site being handed over up to the date of the final completion of the works by the Contractor, he shall take all measures
necessary for preventing the ingress of vermin, and for protecting and controlling vehicles, pedestrians, livestock, other property, etc, on the sections
of the properties affected by his operations. He shall provide gates at the positions in existing fences cut by him for gaining access and shall ensure
that all gates are kept closed except when they are opened for admitting his traffic. No fences shall be cut for access without the approval of the
Engineer, and consultation with the owner/rights holder of the adjoining property.
Where alternative arrangements cannot be made, the Engineer may direct the Contractor to erect temporary fencing where necessary to protect
livestock or game that may stray or be lost; or are exposed to vermin through his operations. Such fencing shall be of an adequate standard and
shall be erected ahead of construction operations. The temporary fencing shall be maintained in a good order during construction operations and,
on completion of the work, it shall be removed from the site and all surfaces shall be restored. The Engineer may order that any permanent fencing
which is required erected up ahead of construction operations, where practicable, in lieu of erecting temporary fencing.
When the replacement of fences is required, the Contractor shall either erect the new fence before removing the old fence, or alternatively engage
with the adjoining landowner(s)/rights holders to temporarily remove their stock from the affected camps to enable him to remove the old fence
before erecting the new fences. Payment for any additional cost of restricted working conditions in replacing of fences shall not be made, but
included in the various rates for the replacement of fencing.

Payment for the protection of livestock during fencing operations, but excluding the cost of erection of temporary fences, shall be included in the
amounts tendered for the Contractor's general obligations as specified in Clause A1.3.2 and Section C1.3 of Chapter 1.

Not generally required for Section A11.5. High security fencing may in certain circumstances be required to be provided under performance based
specifications as specified in the Contract Documentation.
A11.5.5 MATERIALS
It is the Contractor’s responsibility to ensure that the materials delivered to the road shall meet these specified requirements and that proof of
compliance is retained.
where provision has been made in Part C for their reuse or specific disposal.
A11.5.5.2 Straining posts, stays, standards and droppers

Straining posts, stays, standards and droppers shall be of the type, size and length indicated on the drawings.
Timber posts shall comply with the requirements of SANS 457 part 2 or part 3. Timber posts shall be treated in accordance with SANS 10005 with
creosote that complies with SANS 616, or if it is approved by the Engineer it shall be treated with a copper-chrome-arsenic compound for timber
preservation, which complies with SANS 673. The preservative specified in the Contract Documentation shall be used.
Tubular straining posts and stays shall have a wall thickness of at least 2,95 mm and shall be galvanized in accordance with SANS 121, or shall
be painted as specified in Section A13.10 of Chapter 13 as may be required on the drawings. Unless otherwise shown on the drawings, all tubular
posts shall be provided with a 230 mm x 230 mm footplate and a pressed-steel or cast-iron cap. Tubular stays shall have a nominal bore of at least
60 mm.
Unless otherwise specified or shown on the drawings, rolled steel posts shall be 15 or 22 kg/m rails and standards shall be 2,3 kg/m Y-sections.
Rolled steel shall be provided with a protective coating of bitumen or other approved material.
Steel droppers shall be at least 0,56 kg/m ridgeback-pattern droppers, unless otherwise specified or shown on the drawings. Steel droppers shall
be provided with a protective coating of bitumen or other approved material.
A11.5.5.3 Bolts for stays

Bolts shall be galvanized steel bolts of the required length and diameter, which shall not be less than 12 mm. All the necessary bolts, nuts and
washers, shall be supplied with each post. All steel bolts, nuts and washers shall have a hot-dip (galvanized) zinc coating, which complies with the
requirements of SANS 121.
A11.5.5.4 Wire
Barbed wire shall comply with the requirements of SANS 675 for class A zinc coating, and shall be one or more of the following types:
High-tensile-grade steel single-strand 3,15 mm x 2,50 mm oval-shaped zinc-coated wire, with a 2,82 mm equivalent diameter and with a 1,8 mm
diameter barb
High-tensile-grade steel single strand 2,80 mm x 1,90 mm oval-shaped zinc-coated wire, with a 2,31 mm equivalent diameter and with a 1,6 mm
diameter barb. This shall not be used below 500 mm above ground where there is risk of veld fire such as where the dry grass density exceeds
1,0 kg per square metre.
Mild-steel-grade zinc-coated double-strand uni-directional-twist wire, each strand 2,50 mm in diameter with a 1,8 mm diameter barb, for use at any
height above ground.
Barbs shall be spaced at a maximum of 150 mm apart.
Smooth wire shall comply with the requirements of SANS 675 for class A zinc coating and shall be of the types specified below:
Straining wire high-tensile-grade steel 4,0 mm diameter zinc-coated wire for use at any height above ground.
Fencing wire high-tensile-grade steel 2,24 mm diameter zinc-coated wire for use above 500 mm above ground where there is a risk of veld fire.
Tying wire shall comply with the requirements of SANS 675 for class A zinc coating and shall be 2,50 mm diameter mild-steel zinc-coated wire for
tying fencing wire to standards and droppers and 1,6 mm mild-steel zinc-coated wire for tying netting and mesh wire to the fencing wire.
The actual diameter of wire supplied shall equal the specified diameter subject to the appropriate tolerance given in SANS 675.
A11.5.5.5 Diamond mesh

Diamond mesh (chain-link fencing material) shall comply with the requirements of SANS 1373. The width shall be shown on the drawings and the
edge finish shall be both sides clinched or barbed.
The nominal diameter of the wire shall be 2,5 mm and the mesh size shall be 63 mm x 63 mm.
The wire shall be fully galvanized.

A11.5.5.6 Wire netting
Wire netting shall be fully galvanized mild-steel wire with a minimum diameter of 1,8 mm with 75 mm hexagonal mesh.
The height shall be as indicated on the drawings.
A11.5.5.7 Barbed-tape security barrier

Barbed-tape security barrier shall comply with the requirements of SANS 1620. The high-tensile steel wire shall be heavily galvanized (class A),
and the barbed tape and concertina clamps shall also be heavily galvanized (class Z600). The diameter of the roll shall be 950 mm or 700 mm
according to specifications.
A11.5.5.8 Gates
Gates shall be manufactured to the dimensions and details shown on the drawings.
Gates shall be complete in every respect, including hinges, washers, bolts and locking chains attached to the gate.
Gates shall be zinc-coated as specified in SANS 121, or painted as specified in Section A13.10 of Chapter 13, or as indicated on the drawings.
A11.5.5.9 Timber posts for wire mats

Timber posts of the required length and diameter for holding down wire mats where the fence crosses streams shall comply with the requirements
of Clause A11.5.5.2.
A11.5.5.10 Hinge joint mesh

Hinge joint mesh wire shall be zinc-coated in accordance with SANS 675. It shall consist of 2,0 mm diameter high tensile line wires and 2,0 mm
diameter mild steel vertical stay wires twisted or interlocked together in a rectangular grid. Unless otherwise indicated on the drawings or Contract
Documentation, the vertical and horizontal wire spacing shall both be 100 mm. The height of the mesh shall be as indicated on the drawings, or as
specified under the measurement and payment item.
A11.5.5.11 Concrete
Clause A11.1.5.4.

Alternative materials for pedestrian, security or game fences may be specified in the Contract Documentation.

The Contractor shall submit his plant and equipment list for excavating, stockpiling if specified, loading, hauling and installation as part of his
method statement to perform the different elements of the Works.

All excavations for pitching, stonework and protection against erosion shall be excavated in the position and to the required dimensions. Overbreak
in width or depth, unless specified by the Engineer, shall be in filled by the Contractor and shall not be measurable for payment.
A11.5.7.2 Types of fencing

The following types of fences shall be erected in accordance with the dimensions shown on the drawings.
• Stock-proof fences
• Vermin-proof fences
• Pedestrian fences
• Security fences
• Game fences
Where existing fences have to be dismantled and re-erected and the dismantled materials are in usable condition, they shall be erected either to
the same design as the original, but with such modifications as may be specified, or they shall be erected up to one of the standards specified
above.
A11.5.7.3 Clearing and grubbing the fence line

Prior to the removal of indigenous vegetation, verification of compliance with Environmental legislation shall be undertaken.
The fence line shall be cleared over a 2,0 m wide strip, 1,0 m on either side of the centre line of the fence and surface irregularities shall be
smoother and graded so that the fence will follow the general contour of the ground. Clearing and grubbing and the removal of trees shall be

executed as specified in Clause A1.6.7 of Chapter 1.
Any areas outside the road reserve where clearing is not permitted or is impracticable shall not be cleared.
A11.5.7.4 Erecting straining posts and standards

Straining posts shall be erected at all terminal points, gates, low points (as required), corners and bends in the fencing and at all junctions with
other fences. Straining posts shall not be spaced further apart than shown on the drawings. The length of posts above ground shall be such that
the correct clearance between the lowest wire and the ground can be obtained.
Straining posts shall be accurately set in holes and shall be provided with concrete bases to the dimensions shown on the drawings. Care shall be
taken not to destroy or disturb any cadastral boundary beacons particularly at corner or bends in fences. Any disturbed or destroyed cadastral
beacons shall be re-instated by the Contractor at his cost.
Holes shall be dug to the full-specified depth. Where, on account of the presence of rock, the holes cannot be excavated by hand or by pneumatic
tools and the Contractor has to resort to the use of explosives, separate payment for the drilling and blasting operations will be made.
All straining posts shall be braced by means of stays or anchors as shown on the drawings or as directed by the Engineer. Tubular stays, where
used, shall be bolted to the posts.
Standards shall be firmly planted into the ground at the spacing’s shown on the drawings or as directed by the Engineer. The spacing of standards
between any two successive straining posts shall be uniform and not greater than that shown on the drawings. In rock or hard material standards
shall be either driven or set in holes drilled into the rock. The size of drilled holes shall provide a tight fit to the standards. Care shall be taken when
driving steel standards to prevent their buckling or being damaged.
All straining posts and standards shall be accurately aligned and set plumb. Where verandah-type of security fencing is used, the posts shall be
planted with the overhang on the roadside and perpendicular to the direction of the fence. After the straining posts and standards have been firmly
set in accordance with the foregoing requirements, fence wires shall be attached thereto at the vertical spacing shown on the drawings.
A11.5.7.5 Erecting fence wires

All fencing wire shall be tied to the standards or posts to prevent the wires from being displaced or becoming loose. Generally tensioned wires shall
be located to the outside of the road reserve posts to ensure stressing the fence due to animals leaning on fences is transferred directly to the
posts rather than to the tie wires. The wire shall be carefully tensioned without sagging, and true to line, care being exercised not to tension the
wire to such an extent that it will break, or that end, corner, straining or gate posts will be pulled out, or that it will be easily damaged during veld
fires. The effects of temperature during tensioning shall be considered to prevent excessive under or over tensioning due to extreme hot or cold
weather. Each strand of fencing wire shall be securely tied in the correct position hard up to each standard with soft galvanized tying wire. The
tying wire for each strand shall pass through a hole or notch in the standard, while the ends of the tying wire shall be wound at least four times
around the fencing wire to prevent it from moving in a vertical direction.
At all straining posts at terminal points, gates, corners, bends and other specified positions, the fencing wire shall be securely wrapped twice around
the post and secured against slipping by tying the end tightly around the wire by means of at least six snug tight twists.
Where high-tensile wire is used, two long twists may first be made followed by the six tight, snug twists around the post to prevent the wire from
breaking at the first twist. When smooth wire is used, the loose end shall preferably be bent over and hooked into the notch between the fencing
wire and the first twist.
Splices in the fencing wire shall be permitted if made in the following manner with a splicing tool. The end of each wire at the splice shall be taken
at least 75 mm past the splicing tool and wrapped snugly around the other wire by not less than six complete turns with the two separate wire ends
being turned in opposite directions. After the splicing tool has been removed, the space left by it in the spliced wire shall be closed by pulling the
wire ends together. Unused wire ends shall be cut close so as to leave a neat splice.
The gaps between gate posts and the adjacent straining posts shall be fenced off with short lengths of fencing wires.
Droppers shall be tied to each fence wire with soft tying wire in the required position as specified for standards to prevent slippage in a vertical
direction. The spacing of droppers between any two straining posts shall be uniform. Anchoring to structures shall be done as shown on the
drawings.
Barbed-tape security barrier shall be attached to the fence as shown on the drawings at maximum spaces of 1,0 m between tying points. Barbed-
tape security barrier rolls shall be spliced by overlapping for one full circle and tied at four evenly spaced points along the circumference. Spliced
ends shall coincide with the positions of the standards.
A11.5.7.6 Erecting diamond mesh or wire netting

Where vermin-proof, pedestrian or security fences are erected, or where specified by the Engineer, wire netting or diamond mesh shall be stretched
against the fence and properly tied to the fencing wire as shown on the drawings. The diamond mesh or wire netting shall be secured by soft tying
wire at 1,2 m centers along the top and bottom wires and at 3,0 m centers along each of the other fencing wires, unless otherwise shown on the
drawings.
In the case of vermin-proof fencing, vermin shall be prevented from creeping under the fence by either one of the two methods described below as
specified:
• By folding back the bottom 130 mm of the wire netting so that it lies flat on the ground and by tightly packing stones (having a minimum
dimension of 200 mm) end to end on this flap to secure it in position.
• By embedding the lower 130 mm of the wire netting in the ground and thoroughly compacting the earth around it on both sides, to secure the
netting.
A11.5.7.7 Erecting special purpose fencing

Special purpose fencing may be specified where higher security or access control is required. This may include additional elements appended to
standard fencing such as barbs to electrification or complete fencing systems. Due to the variability in such fencing system, the materials, standards
and specifications shall be detailed in the Contract Documentation, drawings and measurement and payment sections.
A11.5.7.8 Closing openings under fences
At ditches, streams, drainage channels or other depressions where the fence cannot be erected so as to follow the general ground contour, the
Contractor shall close the opening under the fence with horizontal barbed wires at 150 mm distances, stretched between additional posts or
straining posts as shown on the drawings or directed by the Engineer. In the case of pedestrian, vermin- proof and security fences the opening
shall be covered with strips of wire netting or diamond mesh 1,0 m wide, fixed to the barbed wires.
In the case of larger streams where damming of debris against the fence would constitute a hazard, the opening below the bottom fencing wire
shall be closed with loose- hanging wire nets. For this purpose additional straining posts shall be planted on both sides of the stream with a cable
consisting of at least live strands of smooth fencing wire stretched between them. Onto this cable vertical strips of diamond mesh hanging down to
ground level shall be fixed. The edges of the various strips of diamond mesh shall be tied to each other so that the entire mat will be raised by
water flowing underneath to leave a free stream area. These mats at streams shall be erected only if specified. If it should be necessary to keep
the bottoms of the mats on the ground, the Engineer may order that timber posts or pipes be fixed horizontally to the bottom ends of the diamond-
mesh strips.
A11.5.7.9 Existing fences

Where a new fence joins an existing fence whether in line or at an angle, the new fence shall be erected with a new straining post positioned at
the terminal of the existing fence.
Existing fences that require to be taken down or moved to a new location shall be dismantled, material not required for re-erection or unsuitable for
re-use shall be neatly stacked at approved locations in accordance with the Engineer's instructions. Fencing wire and wire netting shall be stacked
clear of the ground. Payment will be made only for fences removed In accordance with the written instruction of the Engineer.
Where fences require moving, the Contractor shall re-use all the material, declared to be suitable for this purpose by the Engineer, plus such new
material as may be required to put up the fence again to the standard specified for new fences. The Engineer shall not be responsible for any
delays or costs arising from the breaking of re-used wire during straining.
A11.5.7.10 Erecting gates

Gates shall be erected at the positions indicated by the Engineer. The gates shall be hung on gate fittings in accordance with the requirements
shown on the drawings. Gates shall be so erected as to swing in a horizontal plane at right angles to the gate posts, clear of the ground in all
positions. In pedestrian and security fences the double swing gates shall leave a gap not exceeding 25 mm between them when closed and other
gates shall not be further than 25 mm from the gate post when closed.
The clearance below the gates shall not exceed 75 mm with the gates closed.
A11.5.7.11 Temporary fencing and gates

If required, the Contractor shall erect temporary fencing and gates In accordance with the drawings, Contract Documentation or the Engineer's
instructions. The material and erection shall be in accordance with the provisions of this Section, but the material need not necessarily be new.
Where used materials are offered, they shall nevertheless be in a good condition and approved in advance by the Engineer.
When no longer required, the temporary fencing and gates shall be dismantled and removed.
A11.5.8 WORKMANSHIP
The completed fence shall be plumb, taut, true to line and ground contour, with all posts, standards and stays firmly set. The height of the lower
fencing wire above the ground at posts and standards shall not deviate by more than 25 mm from that shown on the drawings. Other fencing wires
shall not deviate by more than 10 mm from their prescribed vertical positions.
The Contractor shall, on completion of each section of fence, remove all off-cuts and other loose wire or netting, poles and concrete so as to not
create a hazard to grazing animals or a nuisance to the owners or occupiers of the properties.
repaired.

B11.5 FENCING
CONTENTS
B11.5.1 SCOPE
B11.5.2 DEFINITIONS
B11.5.3 GENERAL
B11.5.5 MATERIALS

B11.5.8 WORKMANSHIP
B11.5.1 SCOPE
This Section covers the erecting of new fences, the repair or improvement of existing fences and moving of existing fences where necessary along
the boundaries of the road reserve and elsewhere as indicated on the drawings or as specified by the Engineer. It shall also include the erection
of temporary fences as well as the removal of fencing where specified by the Engineer.
The construction and removal of fencing shall be deemed to be a labour enhanced construction process.
Part A.
B11.5.2 DEFINITIONS
B11.5.3 GENERAL

B11.5.5 MATERIALS


B11.5.8 WORKMANSHIP

C11.5 FENCING
(i) Preamble
1. Unless otherwise ordered or stated in the Contract Documentation, excavations will be measured from the ground surface.
pay items.
km.
specifications.
Clearing and grubbing A11.5.7.3
applicable items
applicable items


C11.5.1 Supply and erect new fencing material for new fences and for supplementing material
in existing fences which are being repaired or removed:
C11.5.1.1 Zinc-coated barbed wire (grade, and size indicated) kilometre (km)
C11.5.1.2 Zinc-coated smooth wire (grade and size Indicated) kilometre (km)
C11.5.1.3 Diamond mesh square metre (m²)
C11.5.1.4 Wire netting square metre (m²)
C11.5.1.5 Barbed-tape security barrier kilometre (km)
C11.5.1.6 Hinge joint mesh square square metre (m2)
C11.5.1.7 Standards (material, protection, length, diameter and type indicated) number (No)
C11.5.1.8 Droppers (material, protection, length, diameter and type indicated) number (No)
C11.5.1.9 Straining posts, stays and anchors:
(a) Vertical
(i) Steel straining posts (type, size and length and whether galvanized or painted indicated) number (No)
(ii) Timber straining posts (protection, length and diameter indicated) number (No)
(b) Inclined
(i) Steel stays and anchors (protection, length, diameter and wall thickness indicated) number (No)
(ii) Timber stays and anchors (protection, length and diameter indicated) number (No)
(iii) Wire stays and anchors (diameter and type indicated) number (No)
(c) Horizontal
(i) Steel stays and anchors (protection, length, diameter and wall thickness indicated) number (No)
(ii) Timber stays and anchors (protection, length and diameter indicated) number (No)
(iii) Wire stays and anchors (diameter and type indicated) number (No)
C11.5.1.10 Extra over items C11.5.1.3; C11.5.1.4 and C11.5.1.6 for stone packing metre (m)
C11.5.1.11 Extra over items C11.5.1.3; C11.5.1.4 and C11.5.1.6 for trenching metre (m)
The quantity of material used shall be determined by measuring the quantities of individual Items of material used in the completed fence. The
linear measurement of the completed fence shall not apply.
The appropriate units of measurement are as follows:
• Straining posts
The unit of measurement shall be the number of posts, vertical; inclined or horizontal, as follows:
All straining posts erected in accordance with the maximum specified spacing or such lesser spacing as authorised by the Engineer, all corner
posts and posts at bends authorised by the Engineer, and all end posts. Wire cross bracing between vertical posts shall not be measured separately
and the cost thereof be deemed to be included in the rate for the posts.
• Standards and droppers
The unit of measurement shall be the number of standards and droppers erected to the maximum specified spacing or such lesser spacing as
authorised by the Engineer.
• Fencing wire (items C11.5.1.1 and C11.5.1.2)
The unit of measurement shall be the kilometre of each type of fencing wire measured between end posts. Tying wire and wire used for anchoring
the posts shall not be measured for payment.
• Diamond mesh, wire netting and hinge joint mesh (items C11.5.1.3; C11.5.1.4 and C11.5.1.6)
The unit of measurement shall be the square metre of diamond mesh, wire netting or hinge joint mesh, the quantity of which shall be calculated

according to the prescribed width and the length between straining posts or gate posts, or the length of strips used for covering openings under
fences, or the length used for covering the gates.
• Barbed-tape security barrier (item C11.5.1.5)
The unit of measurement shall be the kilometre of fencing provided with barbed-tape security barrier of which each concertina is opened to the
maximum effective open concertina length.
• Stays and anchors
The unit of measurement shall be the number of stay and anchor combinations of each type installed.
The tendered rate for each straining post, standard, dropper, each kilometre of fencing wire and barbed-tape security barrier, and each square
metre of diamond mesh, wire netting or hinge joint mesh, and for each anchor or stay shall include full compensation for providing all the materials,
including all concrete, tying wire, straining wire, bolts, washers and nuts, tor excavating or drilling holes for standards, for erecting the posts,
standards and droppers and the complete putting up of the fence as specified and as shown on the drawings. No separate payment will be made
in respect of stone packing and/or trenching in the case of wire netting.
The tendered rates shall also include full compensation for digging all holes. Where, on account of the presence of rock, the holes cannot be
excavated by hand or by pneumatic tools and the Contractor has to resort to the use of explosives, he will be paid separately for the drilling and
blasting operations required under payment item C11.5.7.
C11.5.2 New gates (size and type indicated) number (No)

The unit of measurement shall be the number of new gates erected.
The tendered rates shall include full compensation for procuring and furnishing all material, including gates, zinc-coating, painting, hinges and bolts,
and tor installing the gates complete as specified and as shown on the drawings. It shall not include compensation for any fencing wire or mesh
fitted onto the gate. Gate posts will be paid for under subitem C11.5.1.9(a).
C11.5.3 Moving existing fences and gates:
C11.5.3.1 Fences:
(a) Stock-proof fences kilometre (km)
(b) Vermin-proof fences kilometre (km)
(c) Pedestrian fences kilometre (km)
(d) Security fences kilometre (km)
(e) Game fences kilometre (km)
C11.5.3.2 Gates number (No)

The unit of measurement for moving existing fences shall be the kilometre of fence, the quantity of which shall be taken as the length of fence,
which has been put up permanently with material obtained from fences, which have been dismantled elsewhere. Additional new material used
during the re-erection of existing fences shall be measured under item C11.5.1. The unit of measurement for moving gates shall be the number of
gates moved.
The tendered rate for each kilometre of existing fence moved or for each existing gate moved shall include full compensation for dismantling the
old fence, coiling and stacking the material unsuitable for re-use, moving all material, including posts and wire and again putting up the fence or
gate at the new position and the provision of binding, tying and straining wire. New material used for re-erection of old fences shall be paid for
under item C11.5.1.
The tendered rate for each gate moved shall include lull compensation for taking down the gate and re-erecting it where required, including all new
bolts, nuts and other accessories required but excluding new gate posts.
C11.5.4 Dismantling existing fences and gates:
C11.5.4.1 Fences:
(a) Stock-proof fences kilometre (km)
(b) Vermin-proof fences kilometre (km)
(c) Pedestrian fences kilometre (km)
(d) Security fences kilometre (km)

(e) Game fences kilometre (km)
C11.5.4.2 Gates (type and size indicated) number (No)

The unit of measurement tor the dismantling of existing fences shall be the kilometre of each type taken down and dismantled on the Instruction of
the Engineer. The unit of measurement for the dismantling of gates shall be the number of gates dismantled on the instruction of the Engineer.
The tendered rates shall include full compensation for taking down existing fences and gates, coiling wires, rolling netting into rolls, transporting
the material to designated sites and stacking the material.
C11.5.5 Providing temporary fences and gates:
C11.5.5.1 Stock-proof fence kilometre (km)
C11.5.5.2 Vermin-proof fence kilometre (km)
C11.5.5.3 Pedestrian fence kilometre (km)
C11.5.5.4 Game fences kilometre (km)
C11.5.5.5 Temporary gates (type and size indicated) number (No)

The unit of measurement for items C11.5.5.1 to C11.5.5.4 shall be the kilometre of each type of temporary fencing erected on the instructions of
the Engineer.
The tendered rates shall include full compensation for providing all labour, new or suitable second-hand material putting up the temporary fence
and when no longer required, dismantling and removing it from the site to any new locality where it is required, and for neatly restoring the ground
surface.
The unit of measurement for item C11.5.5.5 shall be the number of temporary gates provided by the Contractor.
The tendered rate shall include full compensation for procuring, supplying and erecting new or second-hand gates, their later removal, and replacing
the gate with fencing.
Where new or second-hand material is used which has been provided by the Employer, e.g. material obtained from taking down existing fences,
such material obtained from taking down the temporary fences or gates shall remain the property of the Employer.
Material provided by the Contractor for temporary fences will similarly become the Contractor's property after the temporary fences have been
dismantled.
C11.5.6 Ringbolts for anchoring fencing to structures number (No)

The unit of measurement shall be the number of ringbolts supplied and fixed to the structure.
The tendered rate shall include full compensation for supplying and fixing ringbolts of the type shown on the drawings to the structure, including,
where necessary, drilling holes, anchorage, grouting ringbolts in with epoxy resin, and for all Incidentals.
C11.5.7 Drilling and blasting holes for posts and anchors number (No)
The unit of measurement shall be the number of holes for posts and anchors made by drilling where excavation by hand or by pneumatic tools
cannot be done economically.
The tendered rate shall include full compensation for drilling and blasting the holes and for all other expenses in connection with providing, storing,
transporting and using explosives.

C11.5.8 Posts fixed horizontally to the bottom of wire mesh for the closing of openings under
fences:
C11.5.8.1 Timber posts (diameter indicated) metre (m)
C11.5.8.2 Mild steel pipes (diameter and wall thickness indicated) metre (m)
The unit of measurement shall be the metre of post of each type installed.
The tendered rate shall include full compensation for procuring, furnishing and fixing the posts, complete as specified and as shown on the drawings.
C11.5.9 Repairing existing fences (Type indicated) kilometre (km)

The unit of measurement for repairing existing fences shall be the kilometre of existing fence repaired on the instruction of the Engineer.

The tendered rate shall include full compensation for untying the existing fence (where necessary) and reinstating it, tying of droppers and repairing
and re-aligning of standards to the satisfaction of the Engineer as well as for coiling and stacking material unsuitable for re-use. Fencing material
replaced shall be paid for under items C11.5.1 and C11.5.2.
If the existing fence is damaged by the Contractor’s construction activities, the Contractor shall repair the fence at his own cost.
C11.5.10 Disposal of existing fencing materials
C11.5.10.1 Type indicated kilometre (km)
C11.5.10.2 Etc Type indicated kilometre (km)
C11.5.10.6 Gates (type indicated) number (No)

The unit of measurement of fencing shall be the kilometre of fencing, regardless of condition, disposed of, and the length shall be measured
between the terminals points of the sections removed.
The unit of measurement for gates shall be the number of gates removed regardless of condition including all fittings.
from site and disposal of the fencing, poles, bolts and nuts of gates as scrap including loading, transporting and off-loading. A full record of the
destination of fencing material disposed of shall be provided to the Engineer for control purposes.
Dismantling of fencing shall be measured and paid for under item C11.5.4

D11.5 FENCING
CONTENTS
D11.5.1 SCOPE
D11.5.2 GENERAL

11.6 ROAD SIGNS
CONTENTS
A11.6.1 SCOPE
A11.6.2 DEFINITIONS
A11.6.3 GENERAL
A11.6.5 MATERIALS
A11.6.8 WORKMANSHIP

A11.6 ROAD SIGNS

A11.6.1 SCOPE
This Section covers the supply of permanent and temporary road signs and the erection of permanent and temporary traffic signs alongside and
over the carriageway, ramps and crossroads at intersections, and interchanges, and at the locations indicated on the drawings or as specified by
the Engineer.
All road signs and traffic signals shall be of the applicable standard regulatory, warning, guidance and information signs or traffic signal requirements
shall be in accordance with the SADC and the South African Road Traffic Signs Manual; as applicable, except where otherwise indicated on the
drawings or in the Contract Documentation, or as specified by the Engineer.
The installation or relocation of permanent traffic signals, cabling and controllers, if required, shall be as specified in the Contract Documentation
and undertaken by specialist sub-Contractors. Provision for payment is provided under Part C under this Section. The construction of ducting and
concrete footings shall be constructed as specified in Section A2.2 of Chapter 2 and Chapter 13 respectively. The provision and operation of
temporary or moveable traffic signals for traffic accommodation and other purposes shall be the undertaken by the Contractor as priced items.
The manufacture and erection of overhead road sign gantries including footings shall be as detailed in Section A13.10 of Chapter 13. The installation
or attachment of road signs thereto shall be undertaken under this Section.
A11.6.2 DEFINITIONS
A11.6.3 GENERAL
No general specifications.

A11.6.5 MATERIALS

It is the Contractor’s responsibility to ensure that the materials delivered to the road shall meet these specified requirements.
where provision has been made in Part C for their reuse or specific disposal.
A11.6.5.2 Materials
a) Structural steel
Structural steel shall comply with the requirements of BS 4360 for the type of steel specified or shown on the drawings. Unless otherwise specified,
channels, square tubes, angle irons and other steel members on the reverse side of the signboards and steel tubes for sign supports shall be
coated In accordance with Clause A11.6.7.2a).
Where specified, all structural steel, including tubes shall be galvanized in accordance with the requirements of SANS 121
Steel tubes shall comply with the requirements of SANS 657.
b) Bolts, nuts and rivets
Steel bolts and nuts shall comply with SANS 135 or SANS 1143. Aluminium bolts and nuts shall be manufactured from alloy B51S or D65S.
Stainless steel bolts, nuts and fasteners shall comply with SANS 1700-5-8, SANS 1700-5-9 or SANS 1700-5-10.
All steel bolts, nuts and washers shall have a hot-dip (galvanized) zinc coating, which complies with the requirements of SANS 121.
Blind rivets used for fixing road signboards to square tubing framework shall be 4,8 mm diameter rivets of sufficient length manufactured from or
coated with a material that prevent corrosion to the rivets or fastened members through electrolytic action. Hardened blind or aluminium rivets shall
be used for attaching aluminium sections.
c) Steel plate and steel profiles
• Steel plate
Steel plate for road signs, prior to the application of any reflective sheeting or painting, shall be 1,4 mm thick Z275 galvanized steel plate, which
has been treated on both sides to the paint system requirements specified inn Table A11.6.5-1.
Table A11.6.5-1: Steel plate paint system requirements
Property Test conditions Method Values
Resistance to UV Weathering QUV-A ASTM G154 After 2000 hrs:
(Colour Change) ISO 7724/1/2/3 ∆E < 2
Resistance to UV Weathering QUV-A ASTM G154 After 2000 hrs:
(Chalking ASTM D659-04 Rating No 8
Resistance to corrosion: Salt Spray ISO 7253 After 1000 hrs:
- Edge creep ASTM D1654 8 mm max
- Blister size ISO 4628/2 2-S2
Bending ASTM D4145 3T, No adhesion loss
Impact resistance ISO 6272 No adhesion loss
Pencil Hardness ASTM D3363 F–H
Scratch Hardness ISO 1518 25-40 N
Dry Film Thickness ISO 2808, 5B Top surface:
38 µm minimum
inclusive of primer
Bottom surface:
20 µm minimum
inclusive of primer
Specular Gloss at 60° At time of coating ISO 2813 25 – 35 %
The reverse side of a STOP sign R1 and all its derivatives shall be painted white. The reverse side of all other signs shall be dark grey.
Where a non-reflectorised road sign is required, its reverse side shall be painted with a dark grey prime coat and the face with only the specified
topcoat.
• Steel profiles
Standard sign profiles shall be 200 mm steel sections with a thickness, prior to the application of any reflective sheeting or painting, be 1,0 mm
thick Z275 galvanized steel plate, which has been treated on both sides to the paint system requirements specified in Table A11.6.5-1), and shall
comply with the details on the drawings.
d) Other plate material
Temporary roadworks delineators signs TW401 and TW402 shall be manufactured from a flexible material and shall comply with the requirements
of SANS 1555. These signs shall either bend or break under vehicular impact and cause minimal damage to vehicles on impact with them. Steel
shall not be used in either the signs or the footings.
Other plate material shall be as specified in the Contract Documentation.
e) Aluminium and aluminium composite
Aluminium flat plate shall be manufactured from grade 5251.H.3 alloy and shall comply with the requirements of BS 1470 and shall be 2,0 mm in
thickness.
Aluminium composite shall be a minimum of 3,0 mm thick composite flat plate, comprising a polyethylene core and two bonded aluminium cover
sheets (AlMg1, EN AW-5005 A alloy), each measuring 0,3 mm inn thickness, with a traffic grey modified polyester system lacquer coating, and

comply to the specifications of SANS 1519-2.
f) Paint
All paints used shall comply with the requirements of SANS 1519-2, including the standards mentioned therein.
In the case of prepainted steel plate, used for non-reflective background signs, the Contractor or supplier shall ensure that the colours and shades
thereof match with those shown in SANS 1091.
g) Retro-reflective material
Retro-reflective material shall be supplied in the following grades and shall comply with the requirements of SANS 1519:
Class I material - 7 year warranty grade
Class III material - 10 year warranty grade
Class IV a) and b) material - 10-12 year warranty grade
The use of materials from different manufactures or different batches for the same colour shall not be used on any one sign.
Materials from different manufacturers shall not be overlaid without specific approval of the Engineer and subject to such conditions as the Engineer
may impose.
The material shall be supplied with a pressure sensitive adhesive backing protected by a removable lining.
h) Timber posts for road sign supports
Timber posts for road sign supports shall conform to the requirements of SANS 754, shall be equal to or better than strength group B timber posts
and shall be affixed with the SABS mark. The posts shall be treated as specified in Clause A11.4.5.2b)(i). The exposed surface of any cut shall be
given two coats of the specified preservative. Any holes drilled in the timber posts after treatment with the preservative shall be re-treated.
i) Corrosion-protection tape
Corrosion-protection tape used between aluminium and steel shall be a black PVC tape not less than 0,25 mm in thickness, shall be resistant to
ultra-violet rays, and shall have an adhesive backing. The breaking strength of the material shall be more than 3,5 kN/m.
j) Silkscreening and digital printing
Silkscreen or digital printed materials shall comply with the requirements of SANS 1519-1 and the screening or printing of road signs shall only be
acceptable after verification of endorsement by the manufacturer of the retro-reflective material to provide an equal or better service life to the
specified retro-reflective material
k) Black vinyl
Black vinyl material shall provide an equivalent warranty as the lowest class of retro reflective material used on a road sign. Black vinyl shall comply
with the requirements for non-reflective sheeting in SANS 1519-1.
l) Concrete
Clause A11.1.5.4.
m) Alternative materials
Alternative materials for road signage elements may be specified in the Contract Documentation.

The Contractor shall submit his plant and equipment list for excavating, stockpiling if specified, loading and hauling as part of his method statement
to perform the different elements of the Works.

All excavations for road signs shall be excavated in the position and to the required dimensions. Overbreak in width or depth, unless specified by
the Engineer, shall be in filled by the Contractor and shall not be measurable for payment.
A11.6.7.2 Manufacturing of road signboards and supports

The road sign face refers to the semi-matt or fully retro reflective painted background plus the text that includes all letters, symbols, numbers,
arrows, emblems and borders.
The road signboard refers to the assembled sign consisting of the road sign face on the specified plate or profiles, the supporting framework, cross
bracing, struts and connecting mechanisms for mounting onto the sign support structure.
The sign support structure refers to the steel or timber supports on which the road signboard is erected and includes the foundations.
No additional payment will be made for steel members such as amongst others hanging channels and U-bolts that are required to complete and

erect the total sign structure according to the specifications and the drawings.
a) Road signboards
Road signboards shall be manufactured by a manufacturer of road signs being affiliated to a recognised traffic sign manufacturer association such
as SARTSMA or a permit holder under SANS 1519-2. Permanent road signs shall be newly manufactured. Temporary road signs may be previously
used signs, however their condition shall be compliant to the specifications, and shall be subject to the acceptance by the Engineer.
Road signboards shall be manufactured strictly in accordance with the details on the drawings. They shall be manufactured from either steel plate
or steel profiles, or aluminium plate or aluminium composite sections according as specified on the drawings.
Retro-reflective material shall be affixed to the sign face strictly in accordance with the specifications of the manufacturer of the retro-reflective
material.
All lettering shall be accurately affixed to the signboards after the background material has been applied.
In so far as is possible, road signboards shall be manufactured as one unit. Where road signs are manufactured in more than one unit, the completed
units shall be assembled in the workshop prior to delivery to ensure that all sections and legends fit together properly. Joints in road signboards
shall be provided only at locations and to details as shown on the drawings.
Before any sign manufacture commences the Contractor shall ensure that the manufacturer has confirmed that he has received all the relevant
details and information to manufacture the road sign in accordance with the Contract requirements and the Contractor shall make every effort to
ensure that signboards are correct in all respect. Before dispatching the boards from the manufacturer’s factory the Engineer shall be provided with
a 100 mm x 150 mm colour photograph or digital representative of each sign face for verification of the correctness of the legend and layout. Such
verification will not imply final acceptance of the board. If the Contractor is in any doubt as to the correctness of the sign detail, enquiry to Engineer
shall be made for design verification.
• Steel and aluminium plate road signboards
All road signs exceeding 600 mm in length (i.e. measured horizontally) shall be stiffened by a supporting framework as shown on the drawings. On
all rectangular signs the supporting framework shall be positioned so that the distance to the edge of the sign plate shall not exceed 5,0 mm.
When road signboards are made up in sections the sections shall be joined with 10 mm galvanized bolts and nuts through 12 mm holes drilled in
both adjoining members of the supporting framework sections with a maximum horizontal spacing of 500 mm and a maximum vertical spacing of
250 mm. All such drilling shall be done prior to painting.
The framework panels for a particular road signboard shall be equal in size, so that the sign will have a balanced and symmetrical appearance
when viewed from the rear. All such framework panels shall be placed on the rear of the road signboard.
The sign plate shall be riveted to the framework wherever the plate is supported by the framework, and not on the edges only. The rivets shall have
a maximum spacing of 150 mm on condition that even the shortest bracing will not have fewer than three rivets (one at each end and one in the
middle). The colour of the rivets shall be the colour of the background on which they are fixed.
Fastening clamps and/or erection brackets shall be manufactured, positioned and fastened to the framework in accordance with the details on the
drawings. Care shall be taken by the Contractor to ensure that the erection brackets are positioned in such a way that the road sign will be vertically
and horizontally true to line when mounted.
Each sign that does not require a supporting framework shall have two mounting holes of 12 mm diameter each located 25 mm from the sign edges
so that the sign may be erected on a vertical post.
The surface of structural steel for the framework of road signs shall be prepared by it being cleaned with a wire brush and shall either be galvanized,
or powder coated in accordance with SANS 1274 for Type 6 coatings. The colour of the framework shall be Dark Grey (reference number G13, as
shown in SANS 1091).
Direct contact between aluminium and any supporting steel framework shall be avoided by adhering corrosion protection tape to the parts of the
board in contact with the steel frame.
• Steel profile road signboards
Steel profile road signboards shall be manufactured in accordance with the details on the drawings.
Manufactured profiles shall be without length distortion and the front faces of completed signs shall have a uniform flat appearance without inward
or outward bowing of individual profile faces. The corners of each profile shall have sharp bends without excessive rounded corners.
Steel profile road signboards shall not be joined longitudinally unless the length of the sign exceeds 6,0 m. In such a case the sign shall be
manufactured in sections of equal length and joined in accordance with the details on the drawings. Steel profile sections for road signboards shall
be jointed together by blind aluminium rivets or stainless-steel bolts and nuts.
Where possible, letters across the joint between two sections should be avoided. If it cannot be avoided, the letters concerned shall be bisected on
the joint and the edges properly pressed home.
Where steel profile sections are to be faced with retro-reflective background material, it shall be applied in advance to individual sections before
assembly, with the material taken around the face edges of each section for at least 10 mm. Subject to the manufacturers approval, retro-reflective
material shall be heated to facilitate adhesion around the edges and to prevent damage being done to the material. During the heating process the
temperature shall not exceed the manufacturer’s recommendations. Prismatic retro-reflective materials, however, are not required to be folded
around the radius, but the ends shall be securely bonded to the panels.
Where possible, letters across the joint between two sections should be avoided. If it cannot be avoided, the letters concerned shall be bisected on
the joint and the edges properly pressed home, however, prismatic retro-reflective materials are not required to be folded around the radius, but
the ends shall be securely bonded to the panels.
Retro-reflective material to adjoining panels on a sign shall be a visual match of the specified colour.

• Composite plate road signboards
Road signboards shall be manufactured as specified for steel and aluminium plate road signboards as specified in Clause A11.6.7.2a).
b) Welding
All welding of steelwork shall be carried out in accordance with the standards laid down in BS 5135. All welding shall be done before painting,
powder coating or galvanizing. Prepainted steel sheets shall not be welded.
c) Structural steel
The relevant provisions for Structural Steelwork in Section A13.9 of Chapter 13, shall apply to all steel supporting structures for road signs.
d) Galvanizing
Where the galvanizing of structural-steel frames and sign-board supporting structures is specified, it shall be done as far as Is practicable after
welding. Where, however, this is not practicable, the steel sections shall be galvanized before assembly and then welded. All welds shall be
thoroughly cleaned, loose material removed, and dressed, after which the welds shall be coated with two coats of an approved zinc-rich paint.
Unless otherwise specified in the schedule of quantities or the Contract Documentation, galvanized steel will not require painting.
e) Road sign supports
Road sign supports shall be constructed in accordance with the details shown on the drawings.
f) General
Where details for the construction of road signboards, the frame work of the road signboards and their attachment to the supporting steel framework
are not shown on the drawings, the Contractor himself shall design them and submit the details to the Engineer for approval before manufacture.
A11.6.7.3 Road sign faces and painting

a) Colours, symbols and legends
Paint colours, symbols, legends and borders used on road signs shall comply with the applicable statutory provisions, and also with the requirements
of the SADC and South African Road Traffic Signs Manual.
The colours shall conform to the colours and shades specified in SANS 1519-1 & -2.
The templates for all letters, numerals, arrows, borders, symbols, etc or the actual legend itself shall be cut by a method acceptable to the Engineer.
b) Preparing surfaces and applying paint and retro-reflective sheeting
The preparation of surfaces and the painting shall be carried out as specified in Clause A13.10.7 of Chapter 13.
The surface of structural steel for the frames and supports of road signs shall be prepared by it being cleaned with a wire brush and shall then be
coated as specified in Clause A13.10.7 of Chapter 13.
Unless otherwise specified, aluminium road signs, with the exception of painted road signboards, will not require painting Galvanized frameworks
will not require painting.
Road signboards with a semi-matt finish manufactured from pre-painted plate or composite plate of the specified colour shall not require pre-
treatment or painting. No re-painting of these boards shall be accepted.
The preparation of surfaces and application of retro-reflective sheeting shall be done in strict accordance with the recommendations of the sheeting
manufacturer. The preparation of the surface shall receive particular attention: as will the surface of a fully retro-reflective sign background prior to
the application of the legend thereon.
All signs delivered to the site must be provided with a protective material to prevent damage to the sign-faces. The service provider must provide a
patching specialist to repair any signs that are damaged during loading and offloading at their own cost.
c) Date of manufacture
The faces and backs of road signboards and the legend shall not be painted more than six months prior to their erection.
The manufacturer shall paint an identification code on the reverse side of every completed road signboard in the lower corner nearest to the road
surface in a position where the code will not be obscured by the framework or the erection posts. The code shall be in the form X-MM-JJ where X
is the letter used by the manufacturer to Identify the manufacturer and MM·JJ Indicates the month and year of the manufacture. These letters shall
be painted in white (black on STOP signs) and shall not be larger than 50 mm in height.
d) Advertisements
No advertisements may be displayed on or attached to any part or any side of a road signboard or a road sign support.
e) Application of retro-reflective material
Where applied to pre-painted, pre-formed steel sections, retro-reflective material shall be affixed to the sign face strictly in accordance with the
specifications of the manufacturer of the retro-reflective material.
A11.6.7.4 Storage and handling

Finished road signs shall be packaged to prevent damage from signs rubbing against each other and stored vertically. Road signs should be
transported in a covered truck or trailer to prevent water damage. Large signs may be shipped uncrated or unpacked in open or closed trucks or
trailers, provided the signs are secured vertically in racks to prevent damage.
On site, signs and signboards shall be stored on wooden, steel or plastic spacers in the vertical position so that the signs are not in contact with

the ground. There shall be sufficient space between the finished road signboards to permit free air circulation and moisture evaporation. Contact
of road signboards with treated timber and diesel, or storage where road signboards come into contact with dirt or water will not be permitted.
When required, existing or newly erected road signs shall be fully or partially covered with burlap or other approved adequately ventilated material
to obscure destinations that are temporarily Inapplicable or irrelevant. The covers shall be neatly applied and firmly fixed in position so that they will
be able to withstand strong gusts of wind or eddies caused by passing traffic. The fixing shall be done in a way that will not cause any damage to
the road sign face.
The following shall not be allowed on the completed sign face:
• Drilling of holes, except for the fastening of overlays
• Application of any form of adhesive
• Cleaning with any chemicals that are not specifically approved by the manufacturer of the retro-reflective material.
• Covering the sign face with an impermeable material that does not allow free circulation of air during storage.
All signs damaged during offloading, storage and handling shall be repaired at the Contractor’s cost.
A11.6.7.5 Erecting road signs

a) Position
Road signs shall be erected in the positions shown on the drawings or specified by the Engineer.
b) Excavation and backfilling
Excavations for the erection of road signs shall be made according to the dimensions shown on the drawings Where the excavations are to be
backfilled with soil a 1:12 cement: soil mixture shall be made if so specified by the Engineer. The soil or soil-cement mixture shall then be placed
at optimum moisture content in 100 mm thick layers in the excavation and shall be compacted to a minimum of 93 % of MDD.
Where posts or structures are to be fixed in concrete, or where concrete footings are to be cast the concrete, formwork and reinforcement shall
comply with the requirements of Section A13.4 of Chapter 13. The holes shall be completely filled with concrete up to the level shown on the
drawings or indicated by the Engineer. The upper surface of the concrete shall be neatly finished with sufficient fall to ensure proper drainage.
This Clause shall apply to ground-mounted signs only. Excavating and backfilling for the foundations of overhead steel structures are specified and
measured in Section A13.1 of Chapter 13.
When material from the excavations is not suitable for backfilling or for the preparation of soilcrete, suitable material shall be obtained from site or
commercial sources.
c) Erection
Road signboards must be inspected by the Engineer before the boards are taken from the manufacturer to the site for erection the Contractor shall
notify the Engineer at least one (1) week before the said inspections are required
Road signs shall be erected strictly in accordance with the details and instructions on the drawings and as directed by the Engineer. The Contractor
shall take into account the wind speed factor during installation.
During erection, the structural steelwork shall be firmly bolted and protected to prevent buckling or damage from being caused during erection, or
by the equipment used for erection. Posts to which road signs are to be fixed shall be vertical and the undersides of road signs shall be horizontal
after having been erected.
Where timber posts are used for erecting the signs, all holes that are drilled in the timber shall be retreated with two coats of the approved
preservative. A road sign identification number (as indicated on the layout drawings) shall be painted with white enamel paint on the reverse side
of the road signboard, above the month and year of manufacture in 50 mm high letters and numbers on the side closest to the road surface.
Identification numbers on overhead signs shall be painted in a position that is visible from the road shoulder as specified by the Engineer.
After erection, the signboard shall be thoroughly cleaned with a cleaning agent approved by the retro-reflective material’s manufacturer.
All vegetation obstructing the new or replaced sign board shall be removed prior to installation and disposed of by the Contractor at no additional
payment in order to provide clear visibility of the sign to road users.
d) Field welding
All welding done during erection shall comply with the requirements for welding during manufacture.
e) On-site painting
All painting done after the road signs have been erected shall comply with the requirements for painting during manufacture.
All places where the paintwork has been damaged during erection shall be repaired by the Contractor at his own cost to the satisfaction of the
Engineer.
f) Time of erection
Road signs shall be erected immediately prior to the road being opened to public traffic, unless otherwise specified by the Engineer.
g) General
All destinations and route numbers shown on the drawings shall be subject to amendment, and confirmation of the details shall be obtained from
the Engineer before any particular signs may be made.

A11.6.7.6 Protection and maintenance
The Contractor shall protect the completed road signs against damage until they have been finally accepted by the Employer, and he shall maintain
the road sign until the completion of the contract. Damage or defects caused by negligence or faulty workmanship shall be rectified by the Contractor
at his own cost to the satisfaction of the Engineer.
A11.6.7.7 Dismantling, storing and re-erecting existing road signs

Where specified by the Engineer, the Contractor shall dismantle and remove existing road signs, store them, and re-erect them at new positions
indicated. Dismantling shall be done with the least damage possible to the signs.
Where specified by the Engineer, the signs shall be repainted or repaired and new materials shall be used for part or all of the supporting structure.
Existing overhead and ground mounted road signs that are being replaced by new signs shall be dismantled by the Contractor, unless alternative
placement is specified by the Engineer. The removal of existing signs shall be delayed until after replacement signs are erected, unless not
physically possible. Regulatory and warning signage shall in all circumstances be displayed at all times. Where dismantling of an existing sign is
required before erection of the replacement sign, the dismantling shall not take place until immediately before work is to commence on the
replacement, and the replacement shall be completed and the new sign displayed within 72 hours thereafter.
Dismantling shall include sign panels and ground mounted sign supports, unless otherwise specified by the Engineer.
Ground mounted sign supports shall be cut off just below ground level. Material excavated for removal of buried poles shall be replaced, and any
depression made good using excess material from excavation for new signs.
A11.6.8 WORKMANSHIP
A copy of the process control test results shall be submitted to the Engineer for comments.

B11.6 ROAD SIGNS
CONTENTS
B11.6.1 SCOPE
B11.6.2 DEFINITIONS
B11.6.3 GENERAL
B11.6.5 MATERIALS
B11.6.8 WORKMANSHIP
B11.6.1 SCOPE
This Section covers the supply of permanent and temporary road signs and the erection of permanent traffic signs alongside and over the
carriageway, ramps and crossroads at intersections, and interchanges, and at the locations indicated on the drawings or as directed by the Engineer.
The construction of road signs shall be deemed to be a labour enhanced construction process.
Part A.
B11.6.2 DEFINITIONS
B11.6.3 GENERAL

B11.6.5 MATERIALS


B11.6.8 WORKMANSHIP

C11.6 ROAD SIGNS
(i) Preamble
1. Unless otherwise ordered or stated in the Contract Documentation, excavations will be measured from the ground surface.
pay items.
km.
specifications.
applicable items
Overhead road sign supporting structures C11.6.3
applicable items


C11.6.1 Road signboards with painted or coloured semi-matt background. Symbols, lettering
and borders in semi- matt black or in Class I retro-reflective material, where the sign
board is constructed from:
C11.6.1.1 Aluminium sheet (2,0 mm thick):
(a) Area 0 to 0,5 m2 square metre (m2)
(b) Area exceeding 0,5 m2 but not 2,0 m2 square metre (m2)
(c) Area exceeding 2,0 m2 but not 10 m2 square metre (m2)
(d) Area exceeding 10 m2 square metre (m2)
C11.6.1.2 Aluminium composite sheet
(a) Area 0 to 0,5 m2 (indicate plate thickness, 2,0 or 3,0 mm) square metre (m2)
(b) Area exceeding 0,5 m2 but not 2,0 m2 (indicate plate thickness, 2,0 or 3,0 mm) square metre (m2)
(c) Area exceeding 2,0 m2 but not 10 m2 (3,0 mm plate thickness) square metre (m2)
(d) Area exceeding 10 m2 (3,0 mm plate thickness) square metre (m2)
C11.6.1.3 Prepainted galvanized steel plate:
C11.6.1.4 Prepainted galvanized steel profiles (200 mm high panels):
C11.6.1.5 Other material (details indicated):

C11.6.1.6 Extra over items C11.6.1.1 to C11.6.1.4 for attaching signboards to overhead gantry structures square metre (m2)
and overhead to bridges
C11.6.1.7 Regulatory signs, permanent
(a) 600 mm diameter (signboard material, background and symbol retro-reflective class indicated) number (No)
(b) 900 mm diameter (signboard material, background and symbol retro-reflective class indicated) number (No)
1200 mm diameter (signboard material, background and symbol retro-reflective class
(c) number (No)
indicated)

C11.6.1.8 Regulatory signs, temporary
(a) 600 mm diameter (signboard material, background and symbol retro-reflective class indicated) number (No)
(b) 900 mm diameter (signboard material, background and symbol retro-reflective class indicated) number (No)
1200 mm diameter (signboard material, background and symbol retro-reflective class
(c) number (No)
indicated)
C11.6.1.9 Warning signs, permanent
(a) 600 mm size (signboard material, background and symbol retro-reflective class indicated) number (No)
(b) 900 mm size (signboard material, background and symbol retro-reflective class indicated) number (No)
(c) 1200 mm size (signboard material, background and symbol retro-reflective class l indicated) number (No)
(d) 1500 mm size (signboard material, background and symbol retro-reflective class l indicated) number (No)
C11.6.1.10 Warning signs, temporary
(a) 600 mm size (signboard material, background and symbol retro-reflective class indicated) number (No)
(b) 900 mm size (signboard material, background and symbol retro-reflective class indicated) number (No)
(c) 1200 mm size (signboard material, background and symbol retro-reflective class indicated) number (No)
(d) 1500 mm size (signboard material, background and symbol retro-reflective class indicated) number (No)
C11.6.1.11 Supplementary plates to permanent regulatory or warning signs (signboard material, square metre (m2)
background and symbol retro-reflective class indicated)
C11.6.1.12 Supplementary plates to temporary regulatory or warning signs (signboard material, square metre (m2)
background and symbol retro-reflective class indicated)
The unit of measurement for items C11.6.1.1 to 5 and C11.6.1.11 and C11.6.1.12 shall be the square metre of completed road signboard.
The unit of measurement for items C11.6.1.7 to C11.6.1.10 shall be the number of regulatory or warning road signs provided and installed as
specified.
The tendered rate for items C11.6.1.1 to C11.6.1.5 and items C11.6.1.7 to C11.6.1.12 shall include full compensation for procuring and furnishing
all the materials, and for manufacturing and supplying the completed road signboard, including amongst others the supporting framework,
reinforcement, cross bracing, struts, fixing brackets, angle-irons, channel profiles, galvanizing (if specified), painting, retro-reflective or semi-matt
black lettering, symbols, numbers, arrows, emblems and borders, for attaching the road signboard to a road sign support structure and for all
materials, equipment, labour, supervision, nuts, bolts, transport, handling, etc necessary for the manufacture, completion, delivery, installation of
the road sign board complete as specified, and the removal and disposal of all vegetation obstructing the motorists’ view of the new or replaced
sign board. Payment for road sign supports shall be made under item C11.6.3, except for temporary road sign removal and re-erection which is
paid for under traffic accommodation items.
Payment shall distinguish between road signboards made from the various sign board materials specified.
The tendered rate for item C11.6.1.6 shall include full compensation for all additional costs for working at height over trafficked or un-trafficked road
lanes in attaching road signboards to overhead gantry structures or bridges.
C11.6.2 Extra over on item C11.6.1 for using:
C11.6.2.1 Background of retro-reflective material:
(a) Class I square metre (m2)
(b) Class III square metre (m2)
(c) Class IV specify a) or b) square metre (m2)
C11.6.2.2 Lettering, symbols, numbers, arrows, emblems and borders of retro-reflective material:
(a) Class III square metre (m2)
(b) Class IV specify a) or b) square metre (m2)

The area measured for payment shall be the full area of the road sign face as measured in item C11.6.1.
The tendered rates paid extra over subitems C11.6.1 shall include full compensation for the additional cost of providing retro-reflective background,
symbols, lettering, numbers, arrows, emblems and borders of the type specified in each case.

C11.6.3 Road sign supports (overhead road sign structures excluded):
C11.6.3.1 Steel tubing (diameter and wall thickness indicated) ton (t)
C11.6.3.2 Timber (diameter and type indicated) metre (m)

The unit of measurement of supporting structures manufactured from steel tubing shall be the ton of steel tubing used. Bolts and other accessories
shall not be measured.
The unit of measurement for timber supporting structures shall be the metre of each diameter post used. Bolls and other accessories shall not be
measured. Only the actual length of completed posts shall be measured. Cut-off sections shall not be measured.
The tendered rates shall include full compensation for manufacturing, supplying and erecting the road sign supports, including all materials,
equipment, labour, supervision, bolts, screws, rivets, welding and accessories, together with the painting and galvanizing required, treatment of
timber supports and the provision and treatment of breakaway holes in timber supports.
The tendered rates shall also include full compensation for tidying up, clearing, trimming, disposing of material at approved dumping sites provided
by the Contractor, and finishing the area around each sign footing.
Overhead road sign supporting structures shall not be measured and paid for under this item, but under the appropriate items of Chapter 13.
Timber supporting structures will not be paid for until the break-away holes have been drilled and treated as specified.
C11.6.4 Kilometre markers
C11.6.4.1 Kilometre markers on posts (type and post indicated and reference to drawings) number (No)
C11.6.4.2 Replace marker boards on existing kilometre posts square metre (m2)
The unit of measurement for item C11.6.4.1 shall be the number of kilometre markers on posts provided and erected in accordance with the
drawings. Excluded from this item shall be concrete kilometre marker posts measured under item C11.3.2 and C11.3.3. Markerboards shall be
assembled by the supplier prior to delivering on site.
The tendered rate shall include full compensation for all the labour and material, painting, lettering, posts, excavation, backfilling with soil or concrete,
etc, as may be necessary for completing the work in accordance with the details shown on the drawings.
The unit of measurement for item C11.6.4.2 shall be the number of reference marker boards provided and attached to existing kilometre posts in
accordance with the drawings.
The tendered rate shall include full compensation for the manufacturing and supplying of the completed marker boards, for attaching the marker
board to existing posts along the route and for all materials equipment, labour, nuts and bolts necessary for attaching the marker board as specified.

C11.6.5 Excavation and backfilling for road sign supports (not applicable to kilometre posts)
C11.6.5.1 Excavating soft material and backfilling cubic metre (m3)
C11.6.5.2 Excavating soft or intermediate material and backfilling using labour enhanced construction cubic metre (m3)
methods
C11.6.5.3 Extra over item C11.6.5.1 and 2 for cement-treated soil backfill cubic metre (m3)
C11.6.5.4 Extra over item C11.6.5.1 for hard material excavation cubic metre (m3)
C11.6.5.5 Imported backfill material from commercial sources cubic metre (m3)
The unit of measurement for items C11.6.5.1 and C11.6.5.2 shall be the cubic metre of excavation measured in place according to the neat
dimensions of the footings or excavations as shown on the drawings or directed by the Engineer. In the case of timber posts not in concrete, the
plan area of the excavated hole shall be taken as 0,36 m2, irrespective of the actual size of the excavated hole.
The tendered rate shall include full compensation for excavating, backfilling and compacting the backfill material, for the disposal of all surplus
excavated material, and for providing the backfill material.
The unit of measurement for item C11.6.5.3 shall be the cubic metre of excavation backfilled with cement-treated soil, measured as specified for
item C11.6.5.1 and C11.6.5.2.
The tendered rate shall include full compensation for the additional cost of providing and mixing in cement in the backfill material.
The unit of measurement for item C11.6.5.4 shall be the in situ cubic metre of hard material excavated within the excavation limits specified in item
C11.6.5.1

The tendered rate shall include full compensation for the additional cost of excavating in hard material.
C11.6.6 Dismantling, storing and re-erecting road signs with a surface area of:
C11.6.6.1 Area 0 to 0,5 m2 square metre (m2)
C11.6.6.2 Area exceeding 0,5 m2 but not 2,0 m2 square metre (m2)
C11.6.6.3 Exceeding 2,0 m2 but not 10 m2 square metre (m2)
C11.6.6.4 Exceeding 10 m2 square metre (m2)

The unit of measurement shall be the square metre of signs dismantled, stored and re-erected in each size group.
The tendered rates shall include full compensation for dismantling and storing the road signs and supporting structures, transporting the material
to a new location, re- erecting the road signs, and restoring the location where they were dismantled.
Payment for excavations, and the new material and concrete required for re-erecting the road signs shall be made under the appropriate Item, and
any repairs and painting which may be necessary, shall be paid for as additional measurement and payment. No separate payment shall be made
for new bolts and nuts required for such re-erection, the cost of which shall be included in the rates tendered above.
C11.6.7 Dismantling and storing of road signs and overhead signs
C11.6.7.1 Dismantling and storing of road signs with a surface area of:
(c) Exceeding 2,0 m2 but not 10 m2 square metre (m2)
(d) Exceeding 10 m2 square metre (m2)
C11.6.7.2 Dismantling and storing of overhead signs with a surface area of:
(a) Area exceeding 0 m2 but not 2,0 m2 square metre (m2)
(b) Exceeding 2,0 m2 but not 10 m2 square metre (m2)
(c) Exceeding 10 m2 square metre (m2)

The unit of measurement shall be the square metre in each size group dismantled and stored.
The tendered rates shall include full compensation for carefully dismantling and disassembling the road signs and overhead road signs, loading,
transporting, off-loading and carefully stacking all the materials as specified by the Engineer. It shall also include compensation for restoring the
site where the road signs and overhead road signs have been dismantled.
The tendered rates shall also include full compensation for demolishing the concrete footings of existing signs to at least 200 mm below the adjacent
ground level, disposing of the resulting debris at approved dumping sites provided by the Contractor, and cutting timber or steel support structures
at not less than 200 mm below the adjacent ground level.
C11.6.8 Danger plates at culverts/structures
C11.6.8.1 Size 150 x 600 mm (state post type and reflective material) number (No)
The unit of measurement shall be the number of danger plates provided and erected in accordance with the drawings in the Contract Documentation.
The tendered rate shall include full compensation for all labour and material, painting, specified posts, excavation, backfilling with soil etc., as may
be necessary for completing the work in accordance with the details shown on the drawings.

C11.6.9 Installation of traffic signals
C11.6.9.1 Specialist installation of traffic signals Prime cost sum (PC)
C11.6.9.2 Handling cost, profit and all other charges of sub item C11.6.9.1 Percentage (%)
Payment under item C11.6.9.1 for the provision specialist installation of traffic signals shall be made in accordance with the provisions of Chapter
1 and the General Conditions of Contract applicable to Prime Cost Sums.
The tendered percentage under sub-item C11.6.9.2. shall be a percentage of the actual amount spent under sub-item C11.6.9.1 and shall include full
compensation for handling costs, profit and any other costs associated with the specialist installation of traffic signals on site.
C11.6.10 Disposing of road signs with a surface area of:
C11.6.10.1 Area 0 to 0,5 m2 square metre (m2)
C11.6.10.2 Area exceeding 0,5 m2 but not 2,0 m2 square metre (m2)
C11.6.10.3 Exceeding 2,0 m2 but not 10 m2 square metre (m2)

The unit of measurement shall be the square metre of road signs, regardless of condition, disposed of in each size group.
from site and disposal of the road signs, poles, bolts and nuts as scrap including loading, transporting and off-loading. A full record of the destination
of road sign materials disposed of shall be provided to the Engineer for control purposes.
Dismantling of road signs shall be measured and paid for under item C11.6.7.
Note:
Concrete, formwork and reinforcing steel for road sign gantry footings shall be measured and paid for in accordance with the provisions of Section
A13.4 of Chapter 13, but such payment items shall appear under this Section in the schedule of quantities.
C11.6.11 Disposing of overhead road signs:
C11.6.11.1 Up to 10 m2 square metre (m2)

The unit of measurement shall be the square metre of overhead road signs, regardless of condition, disposed of in each size group.
from site and disposal of the overhead road signs, bolts and nuts as scrap including loading, transporting and off-loading. A full record of the
destination of overhead road sign materials disposed of shall be provided to the Engineer for control purposes.
Dismantling of road signs shall be measured and paid for under item C11.6.7.

D11.6 ROAD SIGNS
CONTENTS
D11.6.1 SCOPE
D11.6.2 GENERAL
D11.6.1 SCOPE
As per Clause A11.6.1.
D11.6.2 GENERAL
The Engineer must ensure that the necessary compliance certificates are provided by the Contractor.
Compliance certification required:
• Affiliation of road sign manufacturer to a recognised traffic sign manufacturer association or being a permit holder under SANS 1519-2.
• Compliance of materials used in road signs to SANS 1519-1.

11.7 ROAD MARKINGS AND ROAD STUDS
CONTENTS
A11.7.1 SCOPE
A11.7.2 DEFINITIONS
A11.7.3 GENERAL
A11.7.5 MATERIALS
A11.7.8 WORKMANSHIP

A11.7 ROAD MARKINGS AND ROAD STUDS

A11.7.1 SCOPE
This Section covers the temporary and final marking of the road surface with lines and symbols and the supply and fixing of retro-reflective or solar
powered road studs as indicated on the drawings or specified by the Engineer. This Section also covers the removal of existing road studs and
repair of the road surface, as well as the supply and fixing of temporary road studs as specified by the Engineer, and the removal of existing road
markings. Temporary road marking shall be retro-reflective and serve the purpose of guiding and warning road users during construction processes
and under reduced speed restrictions.
All road markings shall be of the standard regulatory, warning and guidance markings as detailed on the drawings and in accordance with the
SADC and South African Road Traffic Signs Manuals.
Road marking application shall be based on materials conforming to various SANS requirements and divided either on method and type of material
application specification; or alternatively based on performance based application, where the road marking performance shall be monitored and
measured, and payment based on such measured performance over time. Performance based criteria shall be specified in the specifications and
measurement and payment section. Selection of either the method and type of material application specification; or performance based application
shall be as specified by the Engineer but shall be instructed prior to the application of the road marking, and additionally performance based
application shall not be applicable to first road marking application applied after road surfacing, resurfacing or bitumen rejuvenation.
The Contractor shall provide temporary traffic control facilities in accordance with the specifications given in Section A1.5 of Chapter 1 to ensure
traffic safety where work is being executed.
A11.7.2 DEFINITIONS
A11.7.3 GENERAL

A11.7.4.1 Road Marking
Where indicated under the specifications and measurement and payment, road marking shall be a performance based application where payment
shall be based on specified achieved criteria such as reflectivity, luminance, skid resistance measured over fixed periods.
A11.7.4.2 Road Studs

Where indicated under the specifications and the measurement and payment, road studs shall be a performance based application.
A11.7.5 MATERIALS
Materials removed under this Section from existing works, except where provision has been made in Part C for their reuse or specific disposal,
shall be deemed to be the property of the Contractor.
A11.7.5.2 Materials
a) Marking materials
The responsibility for the selection of the appropriate road marking materials for road markings to ensure conformance with the requirements of
this specification rests with the Contractor. The road marking materials shall provide the characteristics for retro-reflectivity, luminance, skid
resistance and durability as required in the material specifications.
Where thermoplastic, also known as hot melt plastic, or Methyl Methacrylate (MMA), also known as cold plastic, is used, the Contractor shall obtain
approved certification, from the manufacturer, that the product complies with the specification and submit this certification to the Engineer.
(i) Road marking paint (solvent borne and water borne)
Road marking paint shall be Type 1 as specified in SANS 731-1 for solvent borne paints and SANS 731-2 for water borne paints.
Only paint, manufactured in a SANS approved and accredited facility shall be accepted. The no-pick-up time of road marking paint
shall comply with the Class 1 requirement in accordance with SANS 731-1 and -2.
The paint shall be delivered at the site in sealed containers marked in accordance with the requirements of SANS 731-1 and -2.
The viscosity of the paint shall be such that it can be applied according to the manufacturers recommended guidelines for optimum
performance.
(ii) Retro-reflective road marking
Retro-reflective road marking paint shall comply with the requirements of road marking paint in A11.7.5.2a)(i) above with retro
reflective drop on beads complying with SANS 51423. Unless otherwise specified by the Engineer or in the Contract Documents,
the Contractor may select either solvent or water borne paint.
Determination of coefficient of retro-reflected luminance by means of portable retro-reflectometer shall be carried out using
SANS 6261.
(iii) Thermoplastic road marking material
Thermoplastic road marking material shall comply with the requirements of EN 1436, and SANS 51423 for drop-on glass beads for
road marking and anti-skid aggregates and mixtures thereof. Blending of thermoplastic road marking material and glass beads shall
comply with SANS 51424.
The binder shall be a plasticised synthetic resin and the material shall be reflectorised by mixing in a minimum of 20 % by mass
Class A glass beads in accordance with SANS 51424. An additional topping of drop on glass beads shall be applied to the hot
surface of the material for immediate retro-reflectivity.
The white road marking material shall contain 6,0 % by mass minimum titanium dioxide content and shall have a skid resistance of
45 S.R.T. – units or higher. SABS Method 1248 shall be used for determination of traffic wear index; indication of durability.
The following minimum lumination values are required for the completed road marking for performance based application:
250mcd/m2.lux and 120mcd/m2/lux for white & yellow lines respectively, at 30 days after application.
200mcd/m2.lux and 100mcd/m2/lux for white & yellow lines respectively, at 6 months after application.
Determination of coefficient of retro-reflected luminance by means of portable retro-reflectometer shall be carried out using
SANS 6261. The timing for the application of thermoplastic road marking over previously applied marking during the contract period
shall be carried out as specified in the Contract Documentation.
(iv) Methyl Metacrylate (MMA) Cold Plastic Marking Material
Screed applied cold plastic road marking material shall be used for symbols, arrows and letters (hand painted markings) when
specified by the Engineer and shall consist of a solvent-free two component reactive acrylic resin, stuffing, beads and pigment to

which a hardener shall be added. Application is carried out using a trowel, screed box or an appropriate roller. Material applied by
paint brush shall not be used.
Cold plastic road marking material shall be reflectorised by mixing in a minimum of 20 % by mass (or 400g/m2) Class A glass beads
in accordance with SANS 51424. An additional topping of glass beads shall be applied to the wet surface of the material after
application and shall comply with EN 1423
(v) Drop on retro-reflective beads
Retro-reflective glass drop on beads shall be applied to the road marking material before the material dries, cools down or sets.
The beads shall comply with Class A beads in accordance with EN 1424 and SANS 51424.
The beads shall be delivered to site in sealed bags, marked with the name of the manufacturer and the batch identification number.
The Contractor shall, at all times, be in possession of a SANS certificate on site certifying that the beads have been tested with the
requirement of SANS 51424.
(vi) Pre-Formed Road Marking Tape
A pre-formed, conformable polymer layer made from high quality polymeric materials, pigments and glass beads, designed to be
used as an inlay marking on hot asphalt or as an overlay application on concrete and asphalt surfaces.
b) Road studs
Road studs, excluding solar powered road studs, shall comply with the requirements of SANS 1442 or SANS 1463-1 and -2 as required and paid
under the relevant items under Section C11.7 of Part C. Unless otherwise stated in the Contract Documentation, all road studs shall be bi-
directionally reflective; or omnidirectional reflective for circular glass road studs.
Road studs shall be of the size and classification or type specified, based on the drawings in the Contract Documentation. The Contractor shall,
after receiving confirmation of the classification or type and number to be installed from the Engineer, submit to the Engineer samples of the type
of road studs he proposes to supply for approval. The manufactures’ specifications, warranty (if any) installation requirements, forming holes for
anchors and adhesive requirements shall be provided. All studs subsequently used shall be of an equal specification, quality or better. In the event
that manufacturers’ installation specifications are not available, the Contractor shall submit his installation procedure to the Engineer prior to
installation.
Where specified, road studs shall be supplied and installed in accordance with the areas of application set out in Table A11.7.5-1 with reference to
SANS 1463.
Table A11.7.5-1: Areas of application for road studs

Area of Application
Classification
RSA-1 RSA-2 RSA-3 RSA-T
Circular Cats-
Description Bi-directional Bi-directional Bi-directional
Eye
Galvanized steel or Plastic or plastic

Material Glass Plastic
cast iron shell composite
Design Type A Type A Type A Type A
Use Type P Type P Type P Type T
Reflector Type 2 or 3 Type 2 or 3 Type 1 Type 2
Reflectivity PRT1 PRT1 PRT1 PRT0
Installation Anchored road Embedded Self-adhesive or

System Bonded road stud
stud road stud Bonded road stud
Height above
Road H2-H3 H2-H3 H1 H1
Dimensions (min- 100 mm

footprint) 100 mm x 80 mm 100 mm x 100 mm 100 mm x 50 mm
diameter
Colours W–R-Y W – R -Y W W–R-Y
Road Trials S1; R3 S1; R3 S1:R2 Not Applicable
Road stud type and use is classified for the following areas of application:
Road Stud Application 1 (RSA-1): High trafficked center line of narrow roads less than 3,5 m lane width, yellow shoulder line application on single
carriageway roads (1 lane in each direction) where paved shoulder width is wider than 1,5 m.
Road Stud Application 2 (RSA-2): Low to high trafficked centre line application on single carriageway roads (1 lane of at least 3,5 m width in each
direction), and undivided dual carriageways (2 or more lanes in each direction). Low trafficked yellow and all white shoulder line applications on

divided and undivided dual carriageways (2 or more lanes in each direction). All painted island and lane dividing lines at intersections.
Road Stud Application 3 (RSA-3): High trafficked lane dividing lines on divided and undivided dual carriageways (2 or more lanes in each direction).
Road Stud Application T (RSA-T): All temporary deviations and temporary demarcation.
In special circumstances at higher risk locations, solar powered illuminated road studs, of specified colour, shall be installed on instruction of the
Engineer. The Contractor shall, after receiving confirmation of the type and number to be installed from the Engineer, submit to the Engineer
samples of the type of solar powered road studs he proposes to supply for approval. The manufactures’ specifications, warranty, installation
requirements, and adhesive requirements shall be provided. Solar powered road studs shall be installed midway between retro reflective road
studs or as per the drawings.
Solar powered road studs shall conform to the following requirements
• The body of the unit shall be of either UV resistant PVC or aluminium with a shank
• Maximum dimensions are 100 x 100 mm or 100 mm diameter, with an installed maximum height of 22 mm
• The solar panel, electronics and optics shall be sealed inside the unit which shall be waterproof (minimum IP67)
• A suitable power storage battery or capacitor must be incorporated
• Battery life to be 3 years
• The unit must be capable of operating for a minimum of 36 hours continuously after a charge time of 8 hours
• Each unit must be provided with super bright LEDs (18 milli candelas per LED) (number and colour per unit to be as specified in the Contract
Documentation and/or the Schedule of Quantities)
• Operating temperature range -20°C to 60°C
• Compression resistance of unit to be between 200-300 kN
• The spacing of the road studs will be determined by the road geometry, at least 3-4 road studs should be visible at a time

The Contractor shall submit his plant and equipment list for applying, installing or removal of road marking and road studs as part of his method
statement to perform the different elements of the Works.
A11.7.6.1 Mechanical equipment for painting

The equipment shall consist of an apparatus for cleaning the road surfaces, a mechanical road-painting machine, sandblasting equipment and all
additional hand-operated and other equipment necessary for completing the work. The mechanical road marking machine shall be capable of
painting at least three lines simultaneously and shall apply the paint to a uniform film thickness at the rates of application specified hereinafter. The
road-painting machine shall be so designed that it will be capable of consistently painting the road markings to a uniform width with edges and
position within the tolerances specified hereinafter, without the paint running or splashing or spattering, and applying the glass beads simultaneously
with painting. The machine shall further be capable of painting lines of different widths by adjusting the spray jets on the machine or by means of
additional equipment attached to the machine. The road marking machine shall be fitted with a device to guide the operator to the centre of the line
to be painted. This device shall be used at all times of operation.
The machine shall be capable or spraying at a speed of more than 5,0 km/h, and shall be provided with clearly visible amber warning flashing
lights, which shall always be in operation when the machine is on the road. The machine shall always be operated in the same direction as the
traffic flow when applying lane markings under traffic
A11.7.6.2 Thermoplastic heating equipment

Equipment for heating of thermoplastic material shall be so regulated as not to cause heat damage to the thermoplastic material by overheating or
concentrated heating.

A11.7.7.1 Surface preparation
Final road marking shall be applied to newly surfaced bituminous surfaces only after a minimum of 15 days, or such longer period specified due to
climatic conditions, has elapsed, to ensure that no damage or discolouration is caused by volatiles evaporating from the surfacing. However, where
the road is to be opened to traffic before this condition is met, temporary lines shall be painted using water borne road marking paint in the position
of the future final lines. This shall be done as soon as possible after completion of each section of surfacing and before opening to traffic wherever
possible.
Before the road marking is applied, the surface shall be clean and dry and completely free from any soil, grease, oil, acid or any other material,
which will be detrimental to the bond between the paint and the surface. The surface where the paint is to be applied shall be properly cleaned by
means of watering, brooming or compressed air if required. The onus is on the Contractor to ensure that the surface on which the road markings
are to be applied is sufficiently clean and dry to ensure that the quality of the road markings will not be adversely affected. The Contractor is also
responsible for protecting road studs from being painted over, and the subsequent cleaning thereof if such over-painting should occur. Cleaning of
road studs shall be done in such a manner that the functionality of the road studs will not be detrimentally affected by the cleaning agent used.
Where road markings are to be applied to a concrete pavement, all laitance and loose curing compound shall be removed. Concrete primers may

be recommended for specific road marking paints which will require curing times. Particular care shall be taken to ensure that the surface shall be
clean, fresh concrete on all areas where road studs are to be fixed.
No additional payment for cleaning and preparation of the road surface for road marking will be made, and such cleaning and preparation shall be
deemed to be included in the rates for road marking items.
A11.7.7.2 Setting out the road markings

Where road markings are to be replaced after any construction activity, all existing road markings shall be accurately surveyed and referenced
before commencement of any such construction activity which may obliterate the existing road markings. Before commencing with the referencing,
the Contractor shall submit his proposed method of referencing to the Engineer for his approval.
The position of barrier lines shall be re-assessed on site by the Engineer before the Contractor commences with the road marking. The dimensions
and positions of road markings shall be as shown on the drawings or as specified in the appropriate statutory provisions and the SADC and South
African Road Traffic Signs Manual.
The lines, symbols, figures or marks shall be premarked by means of paint spots of the same colour as that of the final lines and marks. These
paint spots shall be at such intervals as will ensure that the traffic markings can be accurately applied, and in no case shall they be more than 1,5
m apart. Normally spots of approximately 10 mm in diameter should be sufficient.
After spotting, the positions of the proposed road markings such as broken lines and the starting and finishing points of barrier lines shall be
indicated on the road. These premarkings shall be approved by the Engineer prior to any painting operations being commenced.
The positions and outlines of special markings shall be produced on the finished road in chalk and shall be approved by the Engineer before they
are painted. Approved templates may be used on condition that the positioning of the marking is approved by the Engineer before painting is
commenced.
The position of road studs shall be marked out on the road and shall be approved by the Engineer before they are fixed in position.
A11.7.7.3 Applying the markings

The Contractor’s establishment on site and general obligation shall be deemed to fully include the establishment of the road marking team,
irrespective of the number of times the road marking team is required to be on site or is required to move within the site or whether markings are
temporary or final.
The figures, letters, signs, symbols, broken or unbroken lines or other marks shall be marked as shown on the drawings or as specified by the
Engineer.
Where the marking is applied by machine, it shall be applied in one layer and operation. Before the road marking machine is used on the permanent
works, the satisfactory operation of the machine shall be demonstrated on a suitable site, which is not part of the permanent works. Adjustments
to the machine shall be followed by further testing. Only when the machine has been correctly adjusted and its use has been approved by the
Engineer after testing, may the machine be used on the permanent work. The operator shall be experienced in the use of the machine.
After the machine has been satisfactorily adjusted, the rate of application shall be checked and adjusted if necessary before application on a large
scale is commenced.
Where two or three lines are required next to each other, the lines shall be applied simultaneously by the same machine. Paint shall be stirred
before application in accordance with the manufacturer's instructions and shall be applied without the addition of thinners.
Where, under special circumstances, painting is done by hand, it shall be applied in two layers, and the second layer shall not be applied before
the first layer has dried out sufficiently. As most road marking paint reacts with the bitumen surface of newly surfaced roads, the paint shall be
applied with one stroke only of the brush or roller.
Solvent and water borne road marking paint shall be applied at a nominal rate of 0,42 ℓ/m2; or as specified as the recommended application rate
by the paint manufacturer; or as specified by the Engineer (non performance based). Spray thermoplastic road marking shall be applied at a
nominal rate of 2,5 kg/m2 to achieve a minimum thickness of 1,25 mm to 1,5 mm; or as specified by the Engineer (non performance based).
Screeded cold plastic road marking shall be applied hand by means of a trowel, screed box or an appropriate roller at a nominal spreading rate of
4,5 kg/m2 to achieve an estimated 2,0 mm material thickness. The desired symbol or line shall be marked with a tape or a template on the road
surface. Thereafter the required volume of material shall be applied and spread uniformly over the entire area. When dry or set, the tape or template
shall be removed.
In order to ensure proper coverage on all types of surfaces the Engineer may order an increase in the above nominal application rates. Payment
for these variations in application rates shall be made under items for variation.
A daily log-sheet, in a format approved by the Engineer, shall be completed and signed by the Contractor and the Engineers representative,
recording the quantities of paint and glass beads used on that day and shall be available for inspection at all times. The completed and signed log-
sheet for the period covered by a payment certificate shall be submitted to the Engineer prior to his approval of the certificate
Where roads are constructed under traffic, solvent or water borne temporary road marking as specified by the Engineer shall be carried out within
14 days of opening the road full width to traffic after the completion of the surfacing, or such other period specified by the Engineer.
If in the opinion of the Engineer, conditions are unsafe, the centre-line shall be painted immediately as temporary road marking after 2,0 km of
continuous road has received a new asphalt layer, or 4,0 km of continuous road has received a new seal surfacing.
A11.7.7.4 Applying the retro-reflective beads

Where retro-reflective road markings are required, the retro-reflective beads shall be applied by means of a suitable machine in one continuous
operation, immediately after the paint has been applied. The rate of application of the beads shall be 400 g/m2or such other rate as may be specified
by the Engineer. Machines which apply the beads by means of gravity only shall not be used. The beads shall be sprayed onto the paint layer by
means of a pressure sprayer.

The thermoplastic road marking material and cold plastic road marking material shall contain intermixed glass beads of minimum content of 20 %
by mass in order to obtain night visibility (reflectivity). The Contractor shall immediately apply additional surface glass beads at 400 g/m2 to obtain
immediate reflectivity. The beads shall be sprayed onto the road marking layer by means of a pressure sprayer. Where letter, symbol, traverse line
and island road marking is undertaken by hand, the glass beads may be applied by hand if approved by the Engineer. Prior to any hand application
work, the Contractor shall first request approval from the Engineer.
Beads shall be applied in accordance with SANS 51423 and SANS 51424.
A11.7.7.5 Installation of road studs

Road studs shall be of the type specified and/or indicated on the drawings and shall be fixed in the positions specified and/or indicated on the
drawings.
Where anchored or embedded road studs are specified the making of anchor holes or embedment holes shall be made in accordance to the
manufacturers specifications or in accordance to an accepted procedure provided by the Contractor.
The road studs shall be fixed by means of an approved epoxy resin or other specified adhesive in accordance with the manufacturer's Instructions,
subject to such amendments to the method as may be specified by the Engineer. Different adhesives shall be used in winter and summer as per
the manufacturers’ specifications. Where road studs are to be replaced after seal work, care must be taken that sufficient adhesive is used so that
the road studs are well supported and bonded. The studs shall be protected against impact until the adhesive has hardened. Before fixing the road
studs, the surface shall be thoroughly cleaned as specified in Clause A11.7.7.1. Where surface bonded road studs are affixed to road surfaces
recently covered with second slurry of a Cape Seal or a texture treated road surface, the risk of delaminating of the upper slurry shall be assessed
prior to using surface bonded road studs.
Permanent road studs shall be fixed after the road marking of the road. Prior to the application of bituminous surface treatment, all existing road
studs shall be adequately protected. Road marking over road studs shall not be accepted. During placement of aggregate chips, rolling and
brooming care shall be taken to protect all existing road studs against damage or breakage. The Contractor shall replace at his own cost any road
studs that have been damaged by constructional activities or that have been stained and cannot be cleaned entirely. Where specified by the
Engineer, the Contractor shall remove the existing road studs prior to the application of the surfacing seal.
Where specified by the Engineer, temporary road studs shall be installed. The Contractor shall maintain the temporary road studs in position until
the final road markings have been completed.
Not more than 5 % loss of road studs during the Defects Notification Period (where applicable) will be accepted. Failure to meet this requirement
shall be rectified at the Contractor’s expense.
A11.7.7.6 Protection
After the road marking has been applied, the markings shall be protected against damage by traffic or other causes. The Contractor shall be
responsible for erecting, placing and removing all warning boards, flags, cones, barricades and other protective measures which may be necessary
in terms of any statutory provisions and/or as may be recommended in the SADC and South African Road Traffic Signs Manual.

Road marking or road studs shall not be applied to a damp road surface or at temperatures lower than 10°C or when in the opinion or the Engineer,
the wind strength is such that it may adversely affect the painting operations.
A11.7.7.8 General
In broken lines the length of segments and the gap between segments shall be as indicated on the drawings. If these lengths are altered by the
Engineer, the ratio of the lengths of the painted section to the length of the gap between painted sections shall remain the same. Lines shall not be
painted more than 3 months prior to the road being opened to public traffic. Where there are risks of previously applied lines wearing through thin
surfacing such as slurries, the new lines shall be applied to match the old lines accurately.
Lines on curves, whether broken or unbroken, shall not consist of chords but shall follow the correct radius. Particularly on curves in the road, and
where roads are widened such as at climbing or passing lanes, the lines shall form continuous single curves without kinks.
The Contractor shall provide a warranty for the road marking, as specified in the Contract Documentation.
Where indicated by the Engineer, the Contractor shall remove existing painted markings from the existing surfaces by means of sand blasting or
as specified by the Engineer. Suitable precautions shall be taken to avoid damage to nearby vehicles or other property during the sand blasting
process.
The use of black paint or chemical paint remover to obliterate existing markings will not be permitted, except where it is specified by the Engineer
as a temporary measure. Where black paint is used, it shall be matt.
A11.7.8 WORKMANSHIP
A11.7.8.1 Faulty workmanship or materials
If any material which does not comply with the requirements is delivered to the site, or is used in the works, or if any work of an unacceptable
quality is carried out, such material or work shall be removed, replaced or repaired as specified by the Engineer at the Contractor's own cost.
Rejected road studs, road markings and paint which has been splashed or dripped onto the pavement, kerbs, structures or other such surfaces,
shall be removed by the Contractor at his own cost, in an approved manner so that the markings or spilt paint will not show up at all.
order to ensure that the quality of work produced will meet the specified requirements for the particular purpose for which it will be used.

A copy of the process control test results shall be submitted to the Engineer for comments.
In order to monitor the application of paint film thickness and application of glass beads the following control mechanisms shall be employed for all
non-performance based road marking:
• At the start of this work, all paint and bead containers shall be recorded and marked together by the Contractor and Engineer and on
completion of the work, all empty containers shall again be recorded, which measures shall be used for calculating the application rates.
• At regular intervals, plates shall be placed in the line of marking and be painted over in order to calculate the paint thickness and bead
application.
• On extended sections of road marking, the spray machines shall be dipped for volume determination at the start and end or each run,
as well as recording the start and end measures of beads. In addition, a discrete marking shall be made at each start and end position
in order to determine the area painted.
• A comprehensive record shall be kept of all the measurements, and submitted to the Engineer on a daily basis.
Property and/or road marking or studs damaged by the Contractor, his personnel, his agents or sub-Contractors shall be repaired or restored to
their condition prior to the damage at the Contractor’s expense.
Temporary road marking is generally non removable on final road surfaces and may be over-painted with final road marking of the specified type,
which requires their positioning and spacing to be sufficiently accurate to allow over-painting to meet the required tolerances
Road markings shall be constructed to accuracy within the tolerances given below:
a) Width
The width of lines and other markings shall not be less than the specified width, nor shall they exceed the specified width by more than 10 mm.
b) Position
The position of lines, letters, figures, arrows, retro-reflective road studs and other markings shall not deviate from the true position by more than
100 mm in the longitudinal and 20 mm in the transverse direction.
c) Alignment of markings
The alignment of the edges of longitudinal lines shall not deviate from the true alignment by more than 10 mm in 15 m.
When an unbroken line and a broken line are painted alongside each other, the beginning and the end of the unbroken line shall coincide with the
beginning of one broken line and the end of another broken line. When existing lines are repainted, the new markings shall not deviate more than
100 mm in the longitudinal direction nor 10 mm in the transverse direction from the existing marking.
The alignment of the road studs shall not deviate from the true alignment by more than 10 mm and shall be positioned so that the reflective faces
are within 5 of a right angle to the centre line of the road
d) Broken lines
The length of segments of broken longitudinal lines shall not deviate by more than 150 mm from the specified length.
e) Testing of plant and equipment
Before applying any final road markings, the Contractor shall satisfy himself and the Engineer, by painting test lines on a section of pavement other
than the section required to be marked:
that the painting machine is in good working order and properly adjusted;
that the operator is fully experienced; and
that the machine sprays at the specified rate of paint application.
The Contractor shall bear the cost of all materials and workmanship required for the above plant tests.
In addition, the Contractor shall conduct random paint thickness tests and dip/spread tests as specified by the Engineer.
While work is in progress, tests shall be carried out on materials and/or the quality of work to ensure compliance with the specified requirements.
The sampling methods are specified in SANS 731-1. The sampling methods described in TMH5 shall be followed where applicable.

B11.7 ROAD MARKINGS AND ROAD STUDS
CONTENTS
B11.7.1 SCOPE
B11.7.2 DEFINITIONS
B11.7.3 GENERAL
B11.7.5 MATERIALS

B11.7.8 WORKMANSHIP
B11.7.1 SCOPE
This Section covers the marking of the road surface with painted lines and symbols and the supply and fixing of retro-reflective road studs as
indicated on the drawings. This section also covers the removal of existing road studs, and the supply and fixing of temporary road studs as
specified by the Engineer, and the removal of existing road markings. Also included is the painting by hand of kerbs to the colours specified.
Part A.
B11.7.2 DEFINITIONS
B11.7.3 GENERAL

B11.7.5 MATERIALS
B11.7.5.1 Road marking paint (solvent borne and water borne)

On certain low order roads and within urban areas, the Engineer may authorise labour enhanced road marking by means of hand held or pushed
equipment using rollers or brushes of the required width or by mobile hand operated pressure applied road marking equipment.

Where road marking or the painting of kerbs by hand is authorised, the Contractor shall demonstrate by means of trial sections that the methods
employed will meet all the required specifications, application rates and tolerances and will be maintained during the work execution.
The Contractor may select the type and make of hand operated line marking equipment subject to executing trial sections to verify to the Engineer
that all the required specifications, application rates and tolerances are achieved and will be maintained during the work execution.
B11.7.8 WORKMANSHIP

C11.7 ROAD MARKINGS AND ROAD STUDS
(i) Preamble
None.
pay items.
5. No separate payment will be made for the hauling of any materials.
C11.7.1 Road marking:
C11.7.1.1 White lines broken or unbroken (paint type and width of line indicated) kilometre (km)
C11.7.1.2 Yellow lines broken or unbroken (paint type and width of line indicated) kilometre (km)
C11.7.1.3 Red lines broken or unbroken (paint type and width of line indicated) kilometre (km)
C11.7.1.4 White lettering and symbols (paint type indicated) square metre (m2)
C11.7.1.5 Yellow lettering and symbols (paint type indicated) square metre (m2)
C11.7.1.6 Red lettering and symbols (paint type indicated) square metre (m2)
C11.7.1.7 Transverse lines, painted island and arrestor bed markings (any colour) (paint type indicated) square metre (m2)
C11.7.1.8 Labour enhanced hand painted white lines broken or unbroken (paint type and width of line square metre (m2)
indicated)
C11.7.1.9 Labour enhanced hand painted yellow lines broken or unbroken (paint type and width of line square metre (m2)
indicated)
C11.7.1.10 Labour enhanced hand painted red lines broken or unbroken (paint type and width of line kilometre (km)
indicated)

C11.7.1.11 Labour enhanced hand painted white lettering and symbols (paint type indicated) square metre (m2)
C11.7.1.12 Labour enhanced hand painted yellow lettering and symbols (paint type indicated) square metre (m2)
C11.7.1.13 Labour enhanced hand painted transverse lines, painted island and arrestor bed markings square metre (m2)
(any colour) (paint type indicated)
C11.7.1.14 Labour enhanced hand painted kerb markings (any colour) (paint type indicated) square metre (m2)
C11.7.1.15 Labour enhanced hand operated pressure applied machine white lines broken or unbroken kilometre (km)
(paint type and width of line indicated)
C11.7.1.16 Labour enhanced hand operated pressure applied machine yellow lines broken or unbroken kilometre (km)
C11.7.1.17 Labour enhanced hand operated pressure applied machine red lines broken or unbroken kilometre (km)
C11.7.1.18 Labour enhanced hand operated pressure applied machine white lettering and symbols square metre (m2)
(paint type indicated)
C11.7.1.19 Labour enhanced hand operated pressure applied machine yellow lettering and symbols (paint square metre (m2)
type indicated)
C11.7.1.20 Labour enhanced hand operated pressure applied machine transverse lines, painted island square metre (m2)
and arrestor bed markings (any colour) (paint type indicated)
C11.7.2 Retro-reflective road marking:
C11.7.2.1 White lines broken or unbroken (paint type and width of line indicated) kilometre (km)
C11.7.2.2 Yellow lines broken or unbroken (paint type and width of line indicated) kilometre (km)
C11.7.2.3 Red lines broken or unbroken (paint type and width of line indicated) kilometre (km)
C11.7.2.4 White lettering and symbols (paint type indicated) square metre (m2)
C11.7.2.5 Yellow lettering and symbols (paint type indicated) square metre (m2)
C11.7.2.6 Red lettering and symbols (paint type indicated) square metre (m2)
C11.7.2.7 Transverse lines, painted island and arrestor bed markings (any colour) (paint type indicated) square metre (m2)
C11.7.2.8 Hand painted white lines broken or unbroken (paint type and width of line indicated) kilometre (km)
C11.7.2.9 Hand painted yellow lines broken or unbroken (paint type and width of line indicated) kilometre (km)
C11.7.2.10 Hand painted red lines broken or unbroken (paint type and width of line indicated) kilometre (km)
C11.7.2.11 Hand painted white lettering and symbols (paint type indicated) square metre (m2)
C11.7.2.12 Hand painted yellow lettering and symbols (paint type indicated) square metre (m2)
C11.7.2.13 Hand painted transverse lines, painted island and arrestor bed markings (any colour) (paint square metre (m2)
type indicated)
C11.7.2.14 Hand operated pressure applied machine white lines broken or unbroken (paint type and kilometre (km)
width of line indicated)
C11.7.2.15 Hand operated pressure applied machine yellow lines broken or unbroken (paint type and kilometre (km)
width of line indicated)
C11.7.2.16 Hand operated pressure applied machine red lines broken or unbroken (paint type and width kilometre (km)
of line indicated)
C11.7.2.17 Hand operated pressure applied machine white lettering and symbols (paint type indicated) square metre (m2)
C11.7.2.18 Hand operated pressure applied machine yellow lettering and symbols (paint type indicated) square metre (m2)

C11.7.2.19 Hand operated pressure applied machine transverse lines, painted island and arrestor bed square metre (m2)
markings (any colour) (paint type indicated)
The unit of measurement for painting the lines shall be a kilometre of each specified colour and width of line and the quantity paid for shall be the
actual length of line painted in accordance with the instructions of the Engineer, excluding the length of gaps in broken lines.
The unit of measurement for painting the lettering, symbols, transverse lines or painted island and arrestor bed markings per required colour shall
be a square metre, and the quantity to be paid for shall be the actual surface area of lettering. Symbols or transverse lines, painted island and
arrestor bed markings completed in accordance with the drawings and Contract Documentation.
The tendered rate per kilometre or per square metre as the case may be for painting the road markings shall include full compensation for
establishing specialist teams and equipment, and for procuring and furnishing all labour and material, including the retro-reflective beads In the
case of retro- reflective paint, and the necessary equipment, and for painting, protecting and maintenance as specified, including the setting-out of
lettering, symbols and transverse lines, painted island and arrestor bed markings, but excluding setting out and premarking the lines. Separate
rates for different types of application are applicable.

C11.7.3 Thermoplastic road marking
C11.7.3.1 Thermoplastic road marking, broken or unbroken (colour and width of line indicated): kilometre (km)
C11.7.3.2 Performance based thermoplastic road marking, broken or unbroken (colour and width of line kilometre (km)
indicated):
C11.7.3.3 Reduced payment for thermoplastic road marking, white lines, broken or unbroken (width of kilometre (km)
line indicated):
C11.7.3.4 Reduced payment for thermoplastic road marking, yellow lines, broken or unbroken (width of kilometre (km)
line indicated):
The unit of measurement for painting the lines shall be a kilometre of each specified width of line and the quantity paid or deducted shall be the
actual length of line painted in accordance with the instructions of the Engineer, excluding the length of gaps in broken lines.
Full payment of the tendered rate will be applicable upon approved completion of the application of the thermoplastic road marking for items
C11.7.3.1 and C11.7.3.2. The tendered rate per kilometre for the road markings shall include full compensation for establishing specialist teams
and equipment, and for procuring and furnishing all material, including the retro-reflective beads and the necessary labour and equipment, and for
marking, protecting and maintenance as specified, including the setting-out of lettering, symbols and transverse lines, painted island and arrestor
bed markings, but excluding setting out and premarking the lines.
Should the coefficient of retro-reflected luminance fall below the required minimum levels as specified in Clause A11.7.5.2a)(iii), payment will be
deducted against item C11.7.3.2 on the following sliding scale under items C11.7.3.3 and C11.7.3 4. No contract price adjustment will be applicable
to any reduced payment.
White lines:
Below 250mcd /m2.lux at 30 days: minus 10 % of the tendered rate; which shall then be termed the reduced rate.
Below 200 down to 180mcd /m2.lux at 6 months: minus 10 % of the reduced rate
2
Below 180 down to 160mcd/m .lux at 6 months: minus 20 % of the reduced rate
2
2
Below 140mcd/m .lux: repainting at Contractor’s expense
Yellow lines:
Below 120 down to 100mcd /m2 at 30 days: minus 20 % of the tendered rate; which shall then be termed the reduced rate.
2
Below 80mcd/m2.lux: repainting at Contractor’s expense
The reduction in the tendered rate applicable for failing to meet the specified minimum luminance level at the 30 days and 6 months measurement
dates shall be applied accumulative in the certificate immediately following the date of measurement
C11.7.4 Cold plastic road marking material
C11.7.4.1 White lettering and symbols square metre (m2)
C11.7.4.2 Yellow lettering and symbols square metre (m2)
C11.7.4.3 Red lettering and symbols square metre (m2)
C11.7.4.4 Transverse lines, painted island and arrestor bed markings (any colour) square metre (m2)
The unit of measurement for applying the roadmarking material for the lettering, symbols, transverse lines, islands and arrestor bed markings shall
be the square metre, and the quantity to be paid for shall be the actual surface area of the lettering, symbols, transverse lines, islands and arrestor
bed markings, completed in accordance with the specifications and on instructions of the Engineer.
The tendered rate per square metre for applying the road marking material shall include full compensation for establishing specialist teams and
equipment, and for procuring and furnishing all material, including the retro-reflective beads and all necessary equipment, and for applying,
protecting and maintenance as specified, including the setting out of lettering, symbols, transverse lines, islands and arrestor bed markings.
C11.7.5 Variations in rate of application:
C11.7.5.1 White paint litre (ℓ)
C11.7.5.2 Yellow paint litre (ℓ)
C11.7.5.3 Red paint litre (ℓ)
C11.7.5.4 Retro-reflective beads kilogram (kg)
C11.7.5.5 Thermoplastic material, all colours kilogram (kg)
C11.7.5.6 Cold plastic marking material, all colours kilogram (kg)

The unit of measurement for variations in the rate of application of the paint and retro-reflective beads shall be a litre and a kilogram respectively
as the relevant unit. These items shall only be relevant to non-performance based road marking
Payment for variations shall be made as specified in item C1.1.4 of Chapter 1.
C11.7.6 Pre formed road marking tape
C11.7.6.1 White (specify width) metre (m)
C11.7.6.2 Yellow (specify width) metre (m)
C11.7.6.3 Red (specify width) metre (m)
The unit of measurement will be for the supply and installation of the pre formed road marking tape on asphalt or concrete surfaces as
specified in Clause A11.7.5.2a)(vi).
C11.7.7 Road studs
C11.7.7.1 Permanent road studs compliant to SANS 1442 (type & colours stated) number (No)
C11.7.7.2 Permanent road studs compliant to SANS 1463 (classification & colours stated) number (No)
C11.7.7.3 Temporary road studs compliant to SANS 1442 or 1463 (type/classification & colours stated) number (No)
C11.7.7.4 Solar powered road studs (No of LED’s & colours stated) number (No)
Provisional sum
C11.7.7.5 Provision of temporary and permanent road studs
(Prov Sum)
C11.7.7.6 Handling cost, profit and all other charges of sub item C11.7.7.5 percentage (%)
C11.7.7.7 Installation only of surface bonded road studs with anchor shanks number (No)
C11.7.7.8 Installation only of surface bonded road studs without anchor shanks number (No)
C11.7.7.9 Installation only of embedded glass road studs number (No)
C11.7.7.10 Installation only of temporary stick on road studs (including removal) number (No)
The unit of measurement for installed road studs shall be the actual number of approved road studs placed in terms of the specifications.
The tendered rate for items C11.7.7.1 to C11.7.7.4 shall include full compensation for establishing specialist teams and equipment, and for
procuring and furnishing all the necessary material, labour and equipment, and for fixing and maintenance as specified. Distinction shall be made
between various types of road studs. Payment under item C11.7.7.5 for the provision on site of approved road studs shall be made in accordance
with the provisions of Section C1.5 of Chapter 1 and the General Conditions of Contract applicable to Provisional Sums.
The tendered percentage under item C11.7.7.6 shall be a percentage of the actual amount spent under item C11.7.7.5 and shall include full
compensation for handling costs, profit and any other costs associated with providing the road studs on site.

The tendered rate for items C11.7.7.7 to C11.7.7.10 shall include full compensation for establishing specialist teams and equipment, and for procuring
and furnishing all the necessary material (excluding the provided road studs), labour and equipment, and for fixing and maintenance as specified.
Distinction shall be made between various types of road stud fixing methods.
No additional payment will be made should temporary or permanent road studs require replacement if lost or broken during the construction period
or during after the issue of the Certificate of Completion in excess of 5 % of installed studs, unless failure is not due to normal tyre impact.

C11.7.8 Setting out and premarking the lines (excluding traffic island markings, lettering and kilometre (km)
symbols)
The unit of measurement for setting out lines shall be the kilometre of lines set out and marked. Where two or three lines are to be premarked for
painted next to each other, and where the centre-to-centre distance between adjacent lines does not exceed 500 mm, the setting-out of all these
lines shall be measured only once.
The tendered rate shall include full compensation for establishing specialist teams and equipment, and for setting out and premarking the lines as
specified, including all necessary equipment, labour and materials.

C11.7.9 Re-establishing the painting unit during the defects notification period and at other number (No)
instances on instruction of the Engineer
The unit of measurement shall be the number of times the painting unit is re-established on site on instruction of the Engineer irrespective of the
number of times the road marking team is required to move within the site.
The tendered rate shall include full compensation for the re-establishment on the site and for later removing all painting and road marking units
including the traffic accommodation requirements and special equipment, personnel, etc, as may be required after instruction by the Engineer. The
Contractor will be paid at tender rates for repainting the road markings. Contract price adjustment at the full index values will apply for this item, if
the work is executed after the issue of the Certificate of Completion.
The establishment and re-establishment of road marking teams and equipment on site during the construction period shall not be paid for under
this iitem, and allowance therefore shall be made by the Contractor in his programme and his rates for painting or other general obligation rates.
The rate shall include for any preliminary and general costs applicable after the issue of the Certificate of Completion.
C11.7.10 Removal of existing, temporary or final road markings by:
C11.7.10.1 Sandblasting square metre (m2)
C11.7.10.2 Water-jetting square metre (m2)
C11.7.10.3 Overpainting as temporary measure square metre (m2)

The tendered rate shall include full compensation for establishing specialist teams and equipment, and for the necessary equipment, labour and
materials, for any specific protection measures, accommodation of traffic, and the cleaning of the area of all dust and debris, all as specified.
C11.7.11 Removal of existing road studs number (No)

The unit of measurement shall be the actual number of road studs removed.
The tendered rate shall include full compensation for furnishing all equipment, labour and material to remove the existing road studs as specified
and to repair the road surface in case of any damage, as well as the disposal of the road studs.

D11.7 ROAD MARKINGS AND ROAD STUDS
CONTENTS
D11.7.1 SCOPE
D11.7.2 GENERAL
D11.7.1 SCOPE
Refer to Clause A11.7.1.
D11.7.2 GENERAL
a) Prior to applying any road marking on the road, the Contractor needs to provide the following approved certification from the manufacturer:
SANS 731-1 for solvent borne road marking paints
SANS 731-2 for water borne road marking paints
SANS 51423 for drop on beads
EN 1436 for thermoplastic road marking material
SANS 51424 for Class A glass beads
SANS 731-1 or SANS 731-2 for white paint
b) The Contractor shall provide the road stud manufacturer / supplier's installation specifications for all application adhesives to the Engineer,
prior to installation.

11.8 LANDSCAPING AND PLANTING PLANTS
CONTENTS
A11.8.1 SCOPE
A11.8.2 DEFINITIONS
A11.8.3 GENERAL
A11.8.5 MATERIALS
A11.8.8 WORKMANSHIP

A11.8 LANDSCAPING AND PLANTING PLANTS

A11.8.1 SCOPE
This Section includes all areas affected by construction activities but may also extend to other areas requiring landscaping and planting for functional
or aesthetic purposes. It includes landscaping, grassing, rehabilitation, erosion protections and planting trees and shrubs.
A11.8.2 DEFINITIONS
A11.8.2.1 Weeds
Any declared weeds or alien invader plants (as listed in the Conservation of Agricultural Resources Act), including any tree, shrub, herb, water
plant or any other plant which, on the instruction of the Engineer, poses any problems in specified areas (such as the road reserve, haul roads,
borrow pits, camp sites, stockpile sites, drainage elements, etc.) at certain times or conditions.
A11.8.3 GENERAL

A11.8.5 MATERIALS

A11.8.5.2 Materials
a) Topsoil
Topsoil, as defined in Clause A1.6.2 of Chapter 1, shall be obtained from stockpiles and/or windrows of topsoil which have been prepared as
specified in Clause A1.6.7.6 of Chapter 1.
Where so specified, the Contractor shall procure and furnish topsoil from commercial sources outside the site, after such sources have been
b) Fertiliser/soil-improvement material
The type of fertiliser/soil-improvement material to be used shall be one or more of the following types or any other type of fertiliser/soil-improvement
material specified in the Contract Documentation:
• Soil-improvement materials such as dolomitic lime, basic slag, gypsum, superphosphate and agricultural lime, compost, manure and mulches.
• Fertilisers such as limestone ammonium nitrate, 2:3:2 (22) and 3:2:1 (25).
c) Grass cuttings
Grass cuttings shall be fresh cuttings of an approved type of grass with sufficient root material to ensure good growth.
d) Grass seeds
Only fresh certified seed shall be used and the types of seeds in the seed mixture shall be as specified in the Contract Documentation.
Mixing the various types of grass seeds for obtaining the prescribed grass-seed mixture shall be done on the site in the presence of the Engineer.
At any time during the planting process the Engineer has the right to take samples in order to test the quality of materials and workmanship. Storing
and identifying the grass seeds and the grass-seed mixtures on the site shall be the responsibility of the Contractor.
The grass seed mixture, where required, shall be indigenous to the local area as specified in the Contract Documentation as follows:
(specify type) (specify kg/ha)
etc.
Total (specify kg/ha)
(Specify source of seed if applicable)
e) Trees and shrubs
Plants shall be of the variety and size shown on the drawings or in the Contract Documentation and/or the schedule of quantities.
The Contractor shall supply the required number of plants as shown on the drawings or in the Contract Documentation and/or the schedule of
quantities. Plants must be healthy, shapely, well rooted and disease-free. Plants shall not show any evidence of having been restricted or deformed
at any time. Plants shall be grown specifically to be able to cope with the adverse conditions as experienced in the road reserve and other required
positions. The plants must be hardened off and be exposed to direct sunlight for at least six months prior to planting in the road reserve. A minimum
amount of water/fertiliser should be administered in order to acclimatise the plants for their future environment as specified by the Engineer.
Each tree shall be supplied in a plastic plant container of at least 8 ℓ capacity and shall have a height of at least 1,5 m.
Each shrub shall be supplied in a plastic plant container of at least 4,5 ℓ capacity and shall have a height of at least 0,5 m.
Each plant shall be handled and packed in the approved manner for that species or variety, and all the necessary precautions shall be taken to
ensure that the plants will arrive at the site of the works in an undamaged and healthy condition for successful growth. Trucks used for transporting
plants shall be equipped with covers to protect the plants from windburn. Containers shall be in an undamaged condition.
The Contractor shall ensure that the plants are and remain in good condition and free from pests and diseases and he shall accept full responsibility
for maintaining the plants in a good condition throughout the contract and the maintenance periods. The plants shall be fully maintained and watered
during this period and any losses of plants on account of the lack of care, or are diseased, during the contract period up when they have established,
shall be replaced at the Contractor's cost.
• Grass sods
Grass sods shall be either nursery-grown or veld sods as described below. Both types shall be harvested, delivered, planted and watered within
36 hours unless otherwise specified by the Engineer. The grass sods shall be free from weeds and diseases. Sods delivered to the site shall be
moist and shall have at least 30 mm soil thickness for nursery-grown sods and 50 mm soil thickness for veldsods, at the location of planting or
placement. Sods shall also measure a minimum of 400 mm in width and 500 mm in length and shall retain the minimum dimensions once placed
for planting.
• Nursery-grown sods
These sods shall be of the variety of grass specified in the Contract Documentation. The grass shall have been grown specifically for sod purposes,
mown regularly and cared for to provide an approved uniformity to the satisfaction of the Engineer. It shall be harvested by sod cutting machines
to ensure an even depth of cut with sufficient root material and soil.
The sods shall be free of weeds, weed seeds, insects and fungal diseases.

• Veld sods
These sods may be obtained from commercial or areas approved by the Engineer within or near the site where a suitable type and density of grass
and type of soil are found. These areas shall also be mown regularly and cared for to provide suitable sods to the approval of the Engineer.
f) Anti-erosion materials
Anti-erosion compounds or hydraulic mulches shall consist of an organic or inorganic material to bind soil particles together or form a growth
medium and shall be a proven product able to suppress dust and to form a protective encrustation. The application thereof shall be by means of a
hydroseeding machine and the application rate shall conform to the manufacturer's recommendations, or be as specified by the Engineer. The
materials used shall be of such a quality that sown seeds may germinate and grow through the crust. Hydraulic mulches may comprise of shredded
straw and shall contain at least 25 % by mass of peat moss or paper fibre.
g) Manure
Manure shall, unless another type has been approved by the Engineer, be old sweated, pure kraal manure free from soil, noxious weed seeds or
other undesirable material. It shall not contain any particles that will not pass through a 50 mm screen and shall be approved by the Engineer
before being delivered to the site.
h) Compost
Compost shall be well decayed, friable and free from noxious weed seeds or any other undesirable materials. It shall not contain any particles that
will not pass through a 50 mm screen and shall be approved by the Engineer prior to delivery on the site.

The Contractor shall submit his plant and equipment list for excavating, stockpiling if specified, hydroseeding, loading and hauling as part of his
method statement.

A11.8.7.1 Landscaping the areas
a) Shaping
Areas within the road reserve but outside the road prism which require shaping by means of bulk earthworks such as contoured areas at
interchanges, intersections and rest areas which require earthworks shall be excavated, filled and compacted as required and shaped to the correct
contours to within a tolerance of plus or minus 150 mm. Such work shall be regarded as being earthworks and measurement and payment therefore
shall be made under Chapter 5, except that quantities may be measured by means of a grid system of levels taken at 10 m intervals before and
after shaping or else it may be determined by leveled cross-sections.
b) Trimming
Trimming shall consist of trimming the existing or previously shaped ground to an even surface with the final levels generally following the original
surface, and it is a requirement that the drainage remains effective without ponding. Trimming shall normally be done by grader, or in more confined
or steep areas by bulldozer. If specified and where machine operations are not practicable, because of confined spaces or steep slopes, trimming
shall be done with hand tools. When trimming is done on slopes, the ridges shall be made parallel to the contour. Such ridges shall be approximately
100mm wide, and the centres between the ridges approximately 400 mm. Trimming shall be done where specified by the Engineer generally to
areas inside the road reserve but outside the road prism, i.e. normally outside the tops of cuts or the toes of fills but trimming of rock outcrops will
not be required.
Trimmed surfaces shall be left slightly rough to facilitate a better binding with topsoil or the natural establishing of vegetation.
When subsequent grassing is required or when it is specified by the Engineer, areas previously shaped shall be trimmed as described above to
within a tolerance of plus or minus 100 mm with all undulations following a smooth curve. The above tolerance shall apply only to areas where the
final contours are given on the drawings
During trimming all surface stones in excess of 50 mm in size and all excess material shall be removed. Areas which require sodding shall be
trimmed in such a way that, after cultivation and the application of topsoil, the finished surface of the area shall be at least 30 mm below the top of
adjacent kerbing, channeling or pavement in the event of sodding with nursery grown sods, and at least 50 mm below In the event of veld sods
being placed.
c) Construction plant rates
The Engineer shall be entitled to pay for shaping and trimming as described above on the basis of hourly construction plant rates. The motor grader
and bulldozer to be provided shall each have a flywheel power of not less than 93 kW. All machines shall be in a good condition. Any labour or
other plant required shall be paid for on hourly or daily rates.
A11.8.7.2 Preparing the areas for planting

a) Soil ripping and scarifying
Where soil is too hard to be scarified with a light tractor, the soil shall be ripped up to a depth of 300 mm before it is loosened by a scarifier to a
depth of 150 mm.
b) Areas which do not require topsoil
Where the areas to be grassed consist of organically suitable material, the topsoil shall be loosened by scarifying to a minimum depth of 150 mm.
All loose surface stones exceeding 20 mm in size on areas to be mowed by machine and falling within the road reserve and all surface stones
exceeding 50 mm in size in other areas shall be removed.

Fertilising may still be required as specified in Clause A11.8.7.2d).
In areas with large natural rock, i.e. not blasted or excavated rock, these rocks may be placed or retained so as to look like a natural part of the
landscape.
c) Areas which require topsoil
Where areas to be grassed consist of organically unsuitable material, the surface shall be scarified to a minimum depth of 150 mm before topsoil
is placed to ensure a proper bond between the topsoil and the subsoil. If required, the area shall be ripped and scarified as described A11.8.7.2a)
above.
Topsoil shall be placed on the prepared surfaces and trimmed to the uniform thickness required. The topsoil shall be scarified by means of
handraking or light rotavators and all stones removed as specified for areas not requiring topsoil in subparagraph (b) above.
Areas which will be inaccessible for topsoil being placed mechanically after the construction works have been completed shall be spread with
topsoil and protected against erosion as construction works progress.
d) Fertilising
For all areas to be planted, and on instruction of the Engineer, the Contractor shall have the top 150 mm of the prepared surface including the
topsoil applied analysed to determine the quantity and type of fertiliser which may be required for establishing proper growth conditions for the
grass or to assess the requirement for any soil improvement required. The Engineer shall be furnished with the soli-analysis and subsequent
fertiliser recommendations. Only after approval by the Engineer of the nature and quantity of the fertiliser, may the application proceed.
Soil-Improvement materials (such as lime, superphosphate, etc) shall be evenly applied over all surfaces where soil improvement is required, and
shall then be thoroughly mixed with the soil to a depth of 150 mm either mechanically or manually. Where hydroseedlng is to be performed, the
fertiliser may be mixed with the anti-erosion compound and water used in the hydroseeding.
e) Vegetation growth media
In certain limited and unique cases, where topsoil is not available or cannot be retained on a steep slope, vegetation growth media such hydraulic
mulches or other media or blankets may be used at an approved application or installation rate, at the specification of the Engineer.
f) General
After an area has been prepared for grassing, the seeding or grassing shall be completed before crustificatlon takes place. Where a crust has been
formed before seeding or grassing is done, the Contractor shall, at his own cost, loosen the crust by scarifying to a depth of 50 mm.
g) Removal of undesirable vegetation
During the course of the contract the Engineer may instruct the Contractor to physically remove undesirable vegetation from within the road reserve.
Such an operation shall take place before the flowering stage of the undesirable vegetation upon written instruction from the Engineer, but shall
not relieve the Contractor of his obligation towards weeding sodded, grassed areas and any area directly affected by any construction activity.
Should the Contractor fail to respond to the written instruction from the Engineer for the removal of the aforementioned undesirable vegetation
before flowering, the Contractor shall be held contractually responsible for any growth or seeding of said vegetation for a period of not less than
twelve (12) months in the affected area.
A11.8.7.3 Grassing
After preparing the areas for planting the method of establishing grass shall depend on the circumstances relating to each case, and the Engineer
shall decide which method is to be used.
a) Planting grass cuttings
The areas to be grassed by means of grass cuttings shall, unless already moist, be thoroughly watered before the cuttings are planted to ensure
that the soil will be uniformly moist to a depth of at least 150 mm when the planting is done. This method shall only be used on flat areas, such as
medians.
An approved variety of grass cuttings shall be evenly planted by hand or mechanically at a rate of at least 600 kg of cuttings per hectare and shall
have the root system of the grass cuttings thoroughly planted within the topsoil layer to ensure good growth. No part of the grass root system shall
be left protruding from the topsoil.
Only fresh cuttings shall be used but not any grass cuttings that have been allowed to dry out. Immediately after having been planted, the grass
cuttings shall be given a copious watering.
b) Sodding
Areas to be grassed by sodding shall be given a layer of topsoil of at least 50 mm in thickness unless, where suitable soil is present, the Engineer
orders the topsoil to be omitted. The areas to be sodded shall be thoroughly watered beforehand so that it will be moist to a depth of at least 150
mm during sodding. The surface shall be roughened slightly to ensure a good penetration of roots into the soil. Sods shall be protected against
drying out and kept moist from the time of harvesting until they are finally placed. The handling of the sods shall not result in the sods losing their
prescribed soil thickness.
The first row of sods shall, where possible, be laid in a straight line, and if on a slope, laying the sods shall start at the bottom of the slope. The
sods shall be butted tightly against each other, and care shall be taken not to stretch or overlap the sods. Where a good fit cannot be obtained, any
intervening spaces shall be filled with topsoil. The next row shall be similarly placed tightly against the bottom row with staggered joints, and so on
until the entire area has been covered with sods. Sods shall be laid in such a way that unnecessary trampling over areas previously laid is prevented.
To this end, a diagonal method of laying sods is preferred, moving up the slope and behind previously laid sods. On steep slopes the sods shall
be held in position by a sufficient number of wooden stakes approximately 300 mm long by 20 mm in thickness and these stakes shall be knocked
in to a depth of 100 mm into the subsoil.
Sods laid adjacent to concrete side drains shall be laid in such a manner that the sodding will be 20 mm higher than the concrete. The top surface
of sods laid adjacent to the road pavement shall be 50 mm lower than the road surface. When stripsodding is required, the sods shall be laid in
such a manner that the sods are proud of the surrounding ground level. During stripsodding the areas in between shall be hydroseeded and

stripsodding shall be staked as specified above.
As sodding is completed each section shall be lightly rolled or firmly pressed to ensure a proper bond with the underlying material, and thoroughly
watered afterwards.
Where it is specified that sodding is required the following sodding principles may be applied:
A 1,0 m wide strip be placed next to the road edge where no gravel shoulder exists. A 0,5 m wide strip be placed adjacent to concrete-lined drains.
Full sodding be used for grass-lined drains. This sodding to extend over the entire drainage channel, including the tops of the sides. The use of
grass sods to commence from the point of acceptance of water, up to the safe discharge of water. No area be left without grass sods within the
drainage channel should it provide a risk of erosion. A minimum of a 1,0 m wide strip be placed over the shoulder breakpoint for fill slopes. Full
sodding to be used for slopes steeper than 1:2. Any slope that exceeds 3,0 m in width be sodded, the type of which be determined by the slope.
c) Hydroseeding
Where it is specified that hydroseeding is to be carried out on topsoil, the thickness of the topsoil layer shall be as specified in the Contract
Documentation or as specified by the Engineer.
The types and mixtures of seeds to be used shall be as specified in the Contract Documentation or, if not so specified therein, shall be agreed on
by the Engineer and the Contractor before any seed of his choice is specified by the Contractor. The Contractor shall be solely responsible for
establishing an acceptable grass cover, and any approval by the Engineer of seed or seed mixtures intended for use by the Contractor shall not
relieve him of this responsibility.
Mulch shall be added to the hydroseeding mix at an approved rate.
Hydroseeding shall then be carried out with an approved hydroseeding machine at a rate of application of not less than 38 kg of seed mixture per
hectare, unless otherwise specified in the Contract Documentation.
When the use of anti-erosion compounds is required and such compound is to be applied simultaneously with the hydroseeding, it shall be mixed
with the hydroseeding mixture before application. Should hydraulic mulches be used, the quantities of the fertilisers shall be adjusted accordingly,
subject to the Engineer's approval.
d) Topsoiling only
Where, in the opinion of the Engineer, the planting of grass or hydroseeding can be dispensed with on account of favourable climatic and other
conditions, the Contractor may attempt to establish grass by topsoiling only. Topsoil shall be selected for the presence of natural grass and seeds
and shall be removed and placed whenever possible at a time that would favour the establishing of grass. These areas shall be treated with an
anti-erosion compound, if so specified by the Engineer. Fertilising shall be done as specified in Clause A11.8.7.2d).
After the topsoil has been placed, it shall be lightly rolled and well-watered, and afterwards watered and mown whenever specified by the Engineer.
The Contractor will not be held responsible for establishing an acceptable grass cover as defined In Clause A11.8.7.3b) when this procedure is
followed, but will be responsible for the consequences of any omission to water or weed the grass as specified by the Engineer.
No payment for grassing shall be made other than for placing topsoil, providing and applying fertilisers and for watering, mowing and weeding the
grass, which will be paid for at the tendered rates. For any replanting of grass on bare patches, repairs caused by erosion, and similar work, the
Contractor will be paid for as a variation in terms of the applicable general conditions of contract.
e) Grassing with an approved grass planter
Grassing shall be done with an approved grass planter which plants the seeds in rows spaced not more than 2,5 mm apart. The planter shall plant
the seeds approximately 6,0 mm deep and shall lightly compact the soil. The prescribed fertiliser may be distributed simultaneously with the grass
planting. The areas shall be thoroughly watered after completion of the operation
f) Sowing by hand
Sowing shall be done by hand particularly on areas inaccessible to machines. The top 20 mm of prepared topsoil shall be raked away in sections,
the seed shall then be spread uniformly within the prepared area. The top 20 mm topsoil shall then be raked over the seedbed, ensuring an even
thickness. This method is to be systematic, and where applicable, follow the contours of any slopes. The areas shall be thoroughly watered after
completion of the operation
The thickness of the topsoil layer shall be as specified by the Engineer. The preparation of the soil of the soil for areas to be grassed is to include
scarifying just before sowing the grass seed. Should erosion of any kind (by animal, wind or rain) have occurred before the Contractor applies the
grass seed, the slope shall be re-instated, at the Contractor’s cost, to its original, erosion free state before seeding commences.
The types and mixtures of seeds to be used shall be as specified in the Contract Documentation. The Contractor shall be solely responsible for
establishing an acceptable grass cover, and any approval by the Engineer of seed mixtures intended for use by the Contractor shall not relieve him
of his responsibility.
g) Other methods of grassing
Other specific methods of grassing may be included under this section in the Contract Documentation.
h) The grassing of borrow pits, temporary deviations, camp sites, access roads and stockpile sites
Prior to any grassing that may be required on such areas, the finishing-off of borrow pits, obliterating the temporary deviations and access roads,
and the clearing of camp sites as described under the relevant Chapters, shall have been carried out as specified in the relevant sections.
A11.8.7.4 Maintaining the grass cover

a) Watering, weeding, mowing and replanting
All sodded and grassed areas shall be adequately watered at regular and frequent Intervals to ensure the proper germination of seeds and growth
of grass until the grass has established an acceptable cover and thereafter until the beginning of the maintenance period of the grass. The quantity
of water and the frequency of watering shall be subject to the Engineer’s approval. With hydroseeding the commencement of watering may be

postponed until a favourable time of the year, but watering shall in any case commence and continue as soon as the seeds have germinated and
growth has started.
The Contractor shall further mow the grass on all areas where grass has been established whenever so specified by the Engineer, until the end of
the defects liability period. All grass cuttings shall be collected and disposed of at no additional cost if so directed by the Engineer. All weeds shall
be eradicated and disposed of by approved means and provision for payment for such operations shall be made under the payment items. Weeds
shall be eradicated before they have a chance to produce seed. Any bare patches where the grass has not taken or where it has been damaged
or has dried out shall be recultivated, planted, sodded or hydroseeded at the Contractor's cost.
All grassed areas shall have an acceptable cover as defined below at both the start and the end of the maintenance period.
b) Acceptable cover
Acceptable grass cover shall mean that not less than 75 % of the area grassed or hydroseeded shall be covered with grass and that no bare
patches exceeding one quarter in any area of 1,0 m x 1,0 m shall occur. In the case of sodding, acceptable cover shall mean that the entire area
shall be covered with live grass at the end of any period not less than three months after sodding.
c) Maintenance period
A maintenance period in respect of grass shall commence when an acceptable grass cover has been certified by the Engineer to have been
established and shall extend for the duration of the contract. During the maintenance period, the Contractor shall be responsible for damage to
grass cover due to his own activities as well as for weeding the vegetated areas.
Any required watering or mowing shall be specified by the Engineer, and paid for under relevant items.
A11.8.7.5 Trees and shrubs

a) Positions of trees and shrubs
Where it is specified that trees and shrubs are required the following general principles shall be applied:
• Trees and shrubs shall be planted at locations shown on the drawings.
• Plants in the median shall be planted in a line 1,5 m from the centre line of the median or as directed by the Engineer. Generally only shrubs
shall be planted in medians.
• When the carriageways are at different levels, the plants in the median shall be planted 3,0 m from the edge of the pavement on the high side
of the median or as directed by the Engineer.
• Where the road curves, the plants in the median shall be planted on the inside of the median centre line.
• Where the carriageways are at different levels as well as on a curve, the plants in the median shall be planted on the high side, provided they
do not impede on sight distance, or as directed by the Engineer.
• At freeway crossings over roads or rivers, shrubs shall be planted in the positions shown on the drawings.
• Care shall be taken not to obscure traffic signs by plants.
• Trees shall not be planted closer than 10 m from the yellow line on the outside shoulder, or as directed by the Engineer.
b) Preparing plant holes
Unless otherwise directed by the Engineer, holes shall be spaced and prepared as follows:
• All holes shall be square in plan.
• Holes for shrubs shall be at least 500 mm square by 600 mm deep at Intervals of at least 1,5 m centre to centre. Alternatively, a 500 mm wide
trench 600 mm deep may be dug, subject to the Engineer's approval.
• Holes for trees shall be at least 700 mm square by 800 mm deep.
• The holes for plants shall be refilled with selected and approved topsoil thoroughly mixed beforehand with manure or compost (one 5 ℓ bucket
full for every shrub hole and one 10 ℓ bucket full for every tree hole) and, depending on soil-analysis, the required quantity and type of fertiliser.
The fill material shall contain an approved water-retaining admixture.
• The holes shall be thoroughly watered before plants are planted. Where the soil is poorly drained, 150 mm of crushed stone shall be placed at
the bottom of the hole before it is filled with soil.
c) Planting
Before trees and shrubs are removed from their containers for planting purposes, they shall be watered to the point of saturation.
Directly after having been planted, each plant shall be well watered with a view to settling the soil. After the soil has settled, additional topsoil
mixture shall be added where necessary to bring the replaced soil in the hole to within 150 mm of the ground surface, so as to ensure that sufficient
water can be retained in the depression around the plant. All trees shall be tied by means of treated sisal rope to two creosote-treated timber stakes
planted firmly in the ground on both sides of the tree directly opposite each other. The distance between the stakes shall be 1,0 m. The stakes
shall have a minimum diameter of 50 mm and shall be at least 300 mm longer than the planted tree, but its length shall not exceed 1,5 m above
ground level.
After planting, the ground surface around the shrubs shall be covered with straw or grass or other type of mulch to minimise evaporation and/or
weed competition.
The ground surface around each tree shall be covered with a plastic membrane with a surface area of 1,0 m2 and a thickness of 150 micron.
Thereafter rocks or stones measuring 150 mm to 250 mm in size shall be placed in a riprap fashion following the contours of the plant hole.
Trees and shrubs shall be considered established once new growth is evident without die-off of portions of the plants, but not less than one month

after planting. The Contractor shall water the trees and shrubs until they are established with payment under the relevant items.
d) Maintenance
A maintenance period in respect of trees and shrubs shall commence when their establishment has been certified by the Engineer and shall extend
for the duration of the contract. During the period of maintenance, the Contractor shall be responsible for damage to plants due to his own activities
as well as watering the trees and shrubs when necessary and keeping the plants free from weeds and pests. Every tree or shrub, which is not
healthy or shows unsatisfactory growth, shall be replaced by the Contractor at his own cost, within one month of having been notified by the
Engineer. Such notification may be given quarterly during the maintenance period. The plants shall be watered in accordance with an agreement
concluded between the Engineer and the Contractor prior to the beginning of the maintenance period.
The watering of plants will be paid for under relevant items.
A11.8.7.6 Alternative slope and erosion protection

Alternative slope and erosion protection methods and materials shall be as specified in the Contract Documentation. These may include vegetation
cylinders or logs attached to slopes, geotextile and organic blankets, topsoil alternatives, etc.
A11.8.7.7 General
a) Time for planting
Grass, trees and shrubs shall be planted as far as is practicable during periods of the year most likely to produce best growing results or dependent
on the germination requirements of the seed mixture. The Contractor shall make every effort to programme his operations in such a manner that
grass, trees and shrubs shall, as far as is possible, be planted during this period.
b) Traffic on grassed areas
The Contractor shall not plant any grass until all operations which may require road-building equipment to be taken over grassed areas have been
completed. No road-building equipment, trucks or water carts shall be allowed onto areas which have been grassed and only equipment required
for the preparations of areas, application of fertiliser and spreading of topsoil will be allowed to operate on areas to be grassed. All damaged areas
shall be reinstated by the Contractor at his own expense.
c) Erosion prevention
During construction the Contractor shall protect all areas susceptible to erosion by installing all the necessary temporary and permanent drainage
works as soon as possible and by taking such other measures as may be necessary to prevent the surface water from being concentrated in
streams and from scouring the slopes, banks or other areas.
Any runnels or erosion channels developing during the construction period shall be backfilled and compacted, and the areas restored to a proper
condition. The Contractor shall not allow erosion to develop on a large scale before effecting repairs and all erosion damage shall be repaired as
soon as possible within the contract period. All topsoil or other material accumulated in side drains shall be removed at the same time. Topsoil
washed away shall be replaced.
d) Proprietary brand materials used for erosion prevention
Certain proprietary brands of materials which may be necessary for erosion prevention to enable natural grass to become established shall, if
required, be specified in the Contract Documentation. The method according to which the material is to be applied, the surface preparation required,
the type of material to be provided and the method of payment shall be as specified in the Contract Documentation or in the suppliers specifications.
e) Responsibility for establishing an acceptable cover
Notwithstanding the fact that the Engineer will determine the method of grassing and that the type of seed or grass used and the rate of application
of the seed may be specified or agreed on by the Engineer and that the frequency of mowing will be as specified by him, the Contractor shall be
solely responsible for establishing an acceptable grass cover and for the cost of replanting grass or rehydroseeding where no acceptable cover
has been established. Where however, in the opinion of the Contractor it is doubtful from the outset if it will be possible to establish an acceptable
cover he may inform the Engineer of his reasons therefore, and the Engineer may, if he agrees, either adopt another method of grassing or agree
to accept whatever cover can be obtained, provided that all reasonable efforts shall be made to establish a good grass cover by the proposed
method. Any such agreement shall be valid only if given in writing by the Engineer beforehand.
In the case of grassing by topsoiling only the Contractor will not be held responsible for establishing an acceptable grass cover but will be held
responsible for the consequences of supplying workmanship, which does not conform to the specifications, or for lack of proper care.
f) Refertilising
Should it become necessary, the Engineer may instruct the Contractor to undertake a refertilising programme on grassed areas during the defects
liability period.
Payment for refertilising will be made under the relevant payment item.
g) Weeding
The Contractor shall maintain all areas affected by construction activities free of all weeds. They shall be removed before the seeding stage of
each species. Should the Contractor fail to remove the alien plant species before seeding he shall be held responsible for weed removal within the
affected area, for an additional period of one year, over and above the contractual one year defects liability period.
The method for the removal of weeds shall be either by hand, which shall include the removal of the complete root system, or by chemical means,
through the use of a registered selective herbicide. Only a registered, licensed pest control operator, licensed for the industrial application of
herbicides, shall administer the application of herbicides.
h) Establishment of vegetation within areas disturbed by construction activities
The Engineer shall assess any area within the construction boundaries that has been disturbed by construction activities, but which is not scheduled

for formal revegetation within the contract. The assessment shall include whether re-vegetation is required. These disturbed areas, nonetheless
remain the Contractor’s responsibility for the removal of alien vegetation in terms of Clause A11.8.7.5d).
A11.8.8 WORKMANSHIP
repaired.

B11.8 LANDSCAPING AND PLANTING PLANTS
CONTENTS
B11.8.1 SCOPE
B11.8.2 DEFINITIONS
B11.8.3 GENERAL
B11.8.5 MATERIALS
B11.8.8 WORKMANSHIP
B11.8.1 SCOPE
This Section includes all areas affected by construction activities but may also extend to other areas requiring landscaping and planting. It includes
landscaping, grassing, rehabilitation, erosion protections and planting trees and shrubs.
Landscaping and planting shall be deemed to be a labour enhanced construction process.
Part A.
B11.8.2 DEFINITIONS
B11.8.3 GENERAL

B11.8.5 MATERIALS


B11.8.8 WORKMANSHIP

C11.8 LANDSCAPING AND PLANTING PLANTS
(i) Preamble
None.
1. No separate payment will be made for backfilling excess excavations/trimming and disposing of surplus material not removed previously, etc.
or any other contingent work, unless the work is specifically specified or ordered.
pay items.
km.
specifications.
applicable items
Stockpiling of topsoil A11.8.5.2a) and A11.8.7.2c) C1.6.9 of Chapter 1
C11.8.1 Trimming:
C11.8.1.1 Machine trimming square metre (m2)
C11.8.1.2 Hand trimming square metre (m2)
All bulk earth-moving operations as described under shaping in Clause A11.8.7.1a) of Part A shall be measured and paid for under Chapter 5.
The unit of measurement for trimming shall be the square metre of area trimmed on the instruction of the Engineer, including areas trimmed after
having been shaped. No trimming within the road prism including cut and fill slopes shall be measured for payment.
The tendered rates shall include full compensation for trimming the areas to the specified finishing requirements, including the moving of a small
quantity of material which would be inherent in this process and the removal of surplus material and stones. Payment shall distinguish between
machine trimming and hand trimming which shall be specified.

C11.8.2 Trimming using machines for trimming or shaping (alternative to subitem C11.8.1.1):
C11.8.2.1 Bulldozer hour (h)
C11.8.2.2 Motor grader hour (h)
The unit of measurement shall be the hour actually worked by each machine in trimming or shaping areas, when so specified by the Engineer.
Standing time will not be measured. The tendered rates shall include full compensation for furnishing and using the machines, including the cost
of fuel, operators, maintenance, transporting the machine to and from the point where it is to be used, and for all other Incidentals necessary for
carrying out the work.
C11.8.3 Preparing the areas for grassing:
C11.8.3.1 Ripping hectare (h)
C11.8.3.2 Scarifying for loosening topsoil hectare (h)
C11.8.3.3 Topsoiling within the road reserve where the following materials are used:
(a) Topsoil obtained from within the road reserve or borrow areas cubic metre (m3)
(b) Topsoil obtained from commercial sources by the Contractor cubic metre (m3)
C11.8.3.4 Topsoiling of borrowpits by using topsoil obtained from borrow areas or from the road reserve cubic metre (m3)
C11.8.3.5 Providing and applying chemical fertilisers and/or soil-improvement material:
(a) Lime ton (t)
(b) Superphosphate ton (t)
(c) Limestone ammonium nitrate ton (t)
(d) 2:3:2 (22) ton (t)
(e) 3:2:1 (25) ton (t)
(f) Other fertilisers and / or soil-improvement materials if required ton (t)

• Ripping
The unit of measurement for ripping shall be the hectare of soil ripped. Only areas ripped on the written instructions of the Engineer shall be
measured for payment.
The tendered rate shall include full compensation for ripping complete as specified in Clause A11.8.7.2.
Loosening the soil by scarifying will be paid for under subitem C11.8.3.2.
• Loosening the topsoil by scarifying
The unit of measurement for loosening the topsoil by scarifying shall be the hectare of soil loosened and prepared in accordance with the
specifications. Only areas loosened by scarifying on the written instructions of the Engineer shall be measured for payment.
The tendered rate shall include full compensation for loosening the topsoil by scarifying, removing stones, and levelling and trimming the surface.
• Placing the topsoil
The unit of measurement shall be the cubic metre of topsoil applied at the specified thickness or as directed by the Engineer, measured in situ after
the topsoil has been placed. The quantity shall be calculated from the net area of the topsoiled surface multiplied by the average thickness of the
topsoil but before the grass sods are placed. Any topsoil placed in excess of the average thickness specified or prescribed will not be measured
for payment.
Payment shall distinguish between topsoil obtained from the road reserve and topsoil obtained by the Contractor from commercial sources.
The tendered rates shall include full compensation for loading the topsoil from stockpile or windrow, transport off-loading, placing and spreading it
to the required thickness, levelling it off to a smooth surface for removing any stones as specified and for roughening the surface to be topsoiled.
Loading and hauling, where applicable, shall be measured and paid as specified in Section C1.7 of Chapter 1. The tendered rate for topsoil from
commercial sources shall also include full compensation for transporting the topsoil to the point of eventual use.
• Providing and applying fertiliser and/or soil improvement material
The unit of measurement for fertiliser shall be the ton of each type of fertiliser and/or soil-improvement material specified and applied.

The tendered rates shall include full compensation for furnishing the fertiliser and/or soli-Improvement material, transporting it to the point of use,
spreading and mixing it into the scarified soil or topsoil, irrespective of the method of application.
C11.8.4 Grassing
C11.8.4.1 The planting of grass cuttings (type of grass indicated) hectare (ha)
C11.8.4.2 Sodding by using the following types of sods:
(a) Nursery sods (type of grass specified) square metre (m2)
(b) Veld sods square metre (m2)
C11.8.4.3 Hydroseeding:
(a) Providing an approved seed mixture for hydroseeding kilogram (kg)
(b) Providing an approved mulch kilogram (kg)
(c) Hydroseeding hectare (ha)
C11.8.4.4 Planting grass seed with an approved grass-planting machine hectare (ha)
C11.8.4.5 Hand sowing square metre (m2)
C11.8.4.6 Other methods (specify)
• Planting grass cuttings

The unit of measurement for planting grass cuttings shall be the hectare of established grass with an acceptable grass cover.
The tendered rate shall include full compensation for furnishing and planting the cuttings, watering, weeding, and replanting if necessary, and all
other incidentals, which may be necessary for establishing an acceptable cover and maintaining the grass except mowing.
• Sodding
The unit of measurement for sodding shall be the square metre covered with sods which has an acceptable cover.
The tendered rates shall include full compensation for procuring, excavating, loading, transporting, off-loading, placing and watering the sods, for
replanting dead areas, for watering and weeding the grass, for supplying and placing timber stakes and for all other incidentals, except for mowing,
which may be necessary for establishing an acceptable cover, and maintaining the grass. Payment shall distinguish between nursery-grown sods
and veld sods obtained from within the road reserve or borrow areas. In the case of veld sods the tendered price shall include leveling-off and
trimming areas from which the sods are taken.
• Hydroseeding
The unit of measurement for providing seed shall be the kilogram of seed of the specified seed mixture.
The tendered rate shall include full compensation for procuring, furnishing, mixing and storing the seeds.
The unit of measurement for providing approved mulch shall be the kilogram of mulch.
The tendered rate shall include full compensation for procuring and furnishing the mulch and applying it as specified, or as directed by the Engineer.
The unit of measurement for hydroseeding shall be the hectare of grass established by hydroseeding, which has an acceptable cover.
The tendered rate shall include full compensation for furnishing mulch and mixing it with seed and water and with any anti-erosion compound If
required, applying the mixture, watering, weeding, re-hydroseeding bare patches, and for any other work, except mowing, which may be necessary
for establishing an acceptable cover and maintaining the grass.
The unit of measurement for planting any grass seeds by using an approved planter shall be the hectare of grass with an acceptable cover, where
the seed has been planted with an approved planter.
The tendered rate shall include full compensation for all labour, material, equipment, weeding, and all incidentals, which may be necessary for
planting the grass seeds and establishing an acceptable grass cover. The tendered rate shall also include full compensation for watering the
planted areas until an acceptable grass cover has been established. Payment for the grass seed will be separate payment.
• Hand-sowing
The unit of measurement for hand-sowing the grass seeds shall be the square metre of grass with an acceptable covering on surfaces specified
by the Engineer to be hand-sown.
The tendered rate shall include full compensation for all labour, materials, equipment, weeding, and all incidentals which may be necessary for
planting the grass seeds and establishing an acceptable grass covering. The tendered rate shall also include full compensation for watering the
planted areas until an acceptable grass covering has been established. Payment for the grass seeds shall be separate payment.

• Other methods
Whenever other methods of grassing are specified in the Contract Documentation, measurement and payment shall be as specified.
• General
Half of the payments under item C11.8.4 will become due when the grassing or hydroseeding has been done, and the remainder will become due
when satisfactory cover has been established.
C11.8.5 Watering the grass when established by topsoiling only kilolitre (kℓ)
The unit of measurement for watering areas which have been topsoiled on the Instruction of the Engineer but which have not been hydroseeded
or planted with grass, shall be the kilolitre of water applied on the instructions of the Engineer and calculated from the number of tank loads applied,
multiplied by the capacity of the tank used in each case.
The tendered rate shall include full compensation for procuring, transporting and applying the water as specified.
C11.8.6 Watering the already planted grass, trees and shrubs during the growing season kilolitre (kℓ)
The unit of measurement for watering the grass, trees and shrubs shall be the kilolitre of water used.
The tendered rate shall include full compensation for obtaining, transporting and applying the water.
The Contractor shall keep a careful record of the quantity of water used by him for watering the grass, trees and shrubs planted and shall submit
such Information to the Engineer on a daily basis. When there are times during the normal growing season, as specified in the Contract
Documentation, when the monthly rainfall figure is less than 75 % of the monthly average, the Contractor will be compensated under this item for
the same percentage of the quantity of water used for watering as that for the monthly rainfall that fell short of the average rainfall.
Note:
The rainfall figures and minimum and maximum temperatures for the contract area are set out in the Contract Documentation.
C11.8.7 Mowing the grass hectare (ha)

The unit of measurement shall be the hectare measured each time when the newly established grass has been cut on the Instructions of the
Engineer.
The tendered rate shall include full compensation for all plant, equipment and labour, required for every cutting of the grass and collection and
disposing of the grass cuttings, ie payment will be made every time the grass has been cut on the instructions of the Engineer.
C11.8.8 Anti-erosion compound or hydraulic mulches (specify type) kilogram (kg)

The unit of measurement shall be the kilogram net mass of anti-erosion compound or hydraulic mulches used with the approval of the Engineer.
The tendered rate for each kilogram of anti-erosion compound or hydraulic mulches applied with the hydroseeding or by itself shall include full
compensation for furnishing the material and mixing and applying it during hydroseeding or by itself.
C11.8.9 Trees and shrubs:
C11.8.9.1 Providing trees and shrubs
(a) Trees (types and size/mass indicated) number (No)
(b) Shrubs (types and size/mass indicated) number (No)
C11.8.9.2 Planting and establishing:
(a) Trees, all types and sizes number (No)
(b) Shrubs, all types and sizes number (No)

The unit of measurement for item C11.8.9.1 shall be the number of each variety of tree or shrub furnished and established.
The tendered rate shall include full compensation for furnishing the plants at the point of final use, including substitutes for plants, which may
become diseased or die.
The unit of measurement for item C11.8.9.2 shall be the number of each type planted and established.
The tendered rates shall include full compensation for excavating the holes to the specified dimensions, furnishing topsoil, wooden stakes, manure
and compost and mixing them together with any fertiliser and water retaining admixture required for planting and refilling each hole with the topsoil

mixture and other soli, for watering the plants until the end of the maintenance period, for weeding and keeping the plants free from pests and
diseases during the maintenance period, furnishing and planting substitutes for plants that have died and for maintaining the plants as specified
until the end of the maintenance period, including any other incidentals which may be necessary for properly executing the work.
The tendered rate for planting and establishing trees shall also include full compensation for furnishing and placing the membrane and riprap stone
pitching at every plant hole, complete as specified.
Any chemical fertiliser and/or soil-improvement material required will be measured and paid for separately.
• General
Seventy-five percent of the payments under Item C11.8.9.2 will become due when the planting has been completed, and the remainder will become
due when satisfactory growth has been obtained.

Provisional sum
C11.8.10 Unspecified work for landscaping
(Prov sum)
The provisional sum allowed shall be expended at the discretion of the Engineer to cover the cost of work in addition to the scheduled items which
may be required in respect of shaping and trimming areas where plant is used at hourly rates, eg the cost of loading and transporting surplus
material, establishing grass by topsoiling only, repairing erosion damage after topsoil has been applied, or any other Items of work required for
which no pay Items have been provided.
Payment shall be made as specified in applicable the general conditions of contract.

C11.8.11 Weeding all grass-seeded areas and the grass when established by topsoiling only hectare(ha)
The unit of measurement for weeding all grass-seeded areas and areas that have been topsoiled on the instruction of the Engineer (but have not
been hydroseeded or planted with grass), shall be the hectare.
The tendered rate shall include full compensation for weeding the prescribed areas in accordance with the specifications.
Note:
Measurement and payment for haul shall be as specified in Section C1.7 of Chapter 1, but no haul shall apply to topsoil paid for from commercial
sources.

C11.8.12 Removal of undesirable vegetation square metre (m2)
The unit of measurement shall be the square metre measured within the road reserve and measured each time the Contractor has been instructed
by the Engineer to remove the undesirable vegetation under this pay item. This item shall not include areas of undesirable vegetation that have
occurred within areas affected by construction activities, and which are considered a contractual obligation
The tendered rate shall include full compensation for all plant, equipment, labour and consumables required to effectively remove the undesirable
vegetation, including the entire root system, and disposing by approved means.

D11.8 LANDSCAPING AND PLANTING PLANTS
CONTENTS
D11.8.1 SCOPE
D11.8.2 GENERAL

11.9 FINISHING THE ROAD AND ROAD RESERVE AND TREATING
OLD ROADS
CONTENTS
A11.9.1 SCOPE
A11.9.2 DEFINITIONS
A11.9.3 GENERAL
A11.9.5 MATERIALS
A11.9.8 WORKMANSHIP

A1.9 FINISHING THE ROAD AND ROAD RESERVE AND TREATING OLD
ROADS
A11.9.1 SCOPE
This Section covers the final finishing and cleaning up of the road and road reserve and all associated works on the site at the completion of
construction, including scarifying and treating old roads, temporary deviations and other temporary works.
Construction may be as new construction, as renewal construction or as a combination of both. When construction includes elements under
Section A1.6 of Chapter 1: Clearing and Grubbing, Chapter 4: Borrow Materials, and Mass Earthworks; and Section A11.8 of Chapter 11:
Landscaping and planting plants, then this Section does not cover the required finishing under those Chapters and Sections.
A11.9.2 DEFINITIONS
A11.9.3 GENERAL
No general requirements.

A11.9.5 MATERIALS
There are no general materials specifications as finishing and cleaning results in the collection and removal of surplus and unwanted excess
material, vegetation and construction litter.
It is the Contractor’s responsibility to ensure that the materials vegetation and other litter collected are disposed of, to approved and authorised
waste disposal sites and not to contravene environmental legislative requirements.
A11.9.5.2 Materials
No specific materials required.

The Contractor shall submit his plant and equipment list for the finishing and cleaning, disposal, stockpiling if specified, loading and hauling as
part of his method statement to perform the different elements of the Works.

A11.9.7.1 Finishing the road and road reserve
For new construction, after completing the seal, surfacing or gravel surfacing on gravel roads; or other final activities where surfacing is not
included, the road and road reserve shall be cleared of all excess earth, stones, boulders, debris, litter, garbage, unwanted vegetation and other
waste or excess material resulting from the construction of the works or the use of the road. All finishing and cleaning not previously done or
required as specified in the sections of the specifications set out in Clause A11.9.1 above, shall be undertaken and completed. This specification,
however, does not intend the finishing, cleaning and maintenance, which must be undertaken as provided for in other Sections of these
specifications, to be postponed until the final finishing operations provided for in this section.
For renewal construction after completing construction work within the site, the Contractor shall ensure that all construction generated or related
material that may have been swept, windrowed, stockpiled, stored or spread beyond the road surface is removed. This shall be done before any
other rehabilitation work is undertaken, including shaping, topsoiling and grassing. Should, during the removal of construction generated or related
material, existing vegetation or topsoil be disturbed or destroyed, the Contractor shall, at his own cost, re-instate the road reserve to its original
state. This shall include ripping, should the construction material and processes have compacted the original surfaces.
Culvert inlets and outlets, culvert barrels, and open drains shall be cleared of debris, soil, silt undesirable vegetation and other material generated
from the construction activities.
The surfacing shall be cleared of all dirt, mud and foreign objects. Brooming or other non-damaging actions shall be used on finished surfacing
and dragging, pushing or scraping material across surfacing shall not be permitted.
All junctions, intersections, islands, kerbing and other elements making up the completed works shall be neatly finished off.
The Contractor shall ensure that all noxious weeds have been removed from the road reserve and borrow pit areas.
All materials resulting from the finishing operations shall be disposed of at approved locations, such as approved waste disposal sites or approved
disused borrow pits. Excess stone in particular from resurfacing operations shall be collected and removed from the site to ensure that future
grass cutting maintenance work will not be hindered by remaining surfacing stone. The Contractor shall make his own arrangements with the
owners of properties on which such materials are to be deposited. Disposal shall be carried out in a neat and uniform manner. Disused materials
such as pipe culverts, not further required and left with approval on adjoining properties, shall be disposed of out of sight from the road to ensure
the road appearance reflects a fully complete and finished project.
All materials resulting from the finishing operations shall be disposed of at approved spoil sites.
A11.9.7.2 Treating old roads

All old roads, temporary deviations, haul roads and construction roads shall, in so far as is practicable, are levelled with the original ground.
Surfaces shall be scarified and broken up to a depth of 150 mm for promoting plant growth.
Where specified by the Engineer, in order to prevent soil erosion, banks, dykes or ditches shall be constructed over the old road to dimensions
All roads and temporary deviations treated as above shall be left in a neat and tidy state.
A11.9.8 WORKMANSHIP
No specific testing of materials is required.

B11.9 FINISHING THE ROAD AND ROAD RESERVE AND TREATING OLD
ROADS
CONTENTS
B11.9.1 SCOPE
B11.9.2 DEFINITIONS
B11.9.3 GENERAL
B11.9.5 MATERIALS

B11.9.8 WORKMANSHIP
B11.9.1 SCOPE
This Section covers the final finishing and cleaning up of the road and road reserve after construction and scarifying and treating old roads and
temporary deviations.
This Section includes work with a large component of labour.
Part A.
B11.9.2 DEFINITIONS
B11.9.3 GENERAL

B11.9.5 MATERIALS


Finishing the road and road reserve and treating old roads shall be deemed to be a labour enhanced construction process.
B11.9.8 WORKMANSHIP

C11.9 FINISHING THE ROAD AND ROAD RESERVE AND TREATING OLD
ROADS
(i) Preamble
None.
1. No separate payment will be made for backfilling excess excavations/trimming and disposing of surplus material not removed previously,
etc. or any other contingent work, unless the work is specifically specified or ordered.
pay items.
km.
specifications.
applicable items
Scarifying for loosening topsoil C11.9 C11.8.3.2
Construction of banks, dykes or open drains C11.9.2 C3.1.6 of Chapter 3
C11.9.1 Finishing the road and road reserve:
C11.9.1.1 Dual carriageway road kilometre (km)
C11.9.1.2 Single carriageway road kilometre (km)

The unit of measurement shall be the kilometre of road measured along the centerline. No separate measurement will be made of ramps at
interchanges or at crossroads where intersections have been constructed.
No distinction shall be made between new works and renewal construction.
The tendered rates shall include full compensation for cleaning, trimming, disposing of material, tidying and all other work to be done for finishing
off the road and road reserve as specified.

C11.9.2 Treatment of old roads and temporary deviations
C11.9.2.1 Conventional construction methods kilometre (km)
C11.9.2.2 By hand only kilometre (km)

The unit of measurement shall be the kilometre of old road or temporary deviation treated.
The construction of banks, dykes or open drains shall be measured and paid for under Section C3.1 of Chapter 3.
The tendered rate shall include full compensation for levelling and scarifying any surfaces and tidying old roads and temporary deviations as
specified.
No payment will be made in regard to treating Contractor constructed haul roads and construction roads not intended for public road users, for
which the Contractor shall make allowance in his rates for constructing the relevant Items of work for which such roads are necessary.

D11.9 FINISHING THE ROAD AND ROAD RESERVE AND TREATING OLD
ROADS
CONTENTS
D11.9.1 SCOPE
D11.9.2 GENERAL

South Africa
COTO
Officials


CHAPTER 12: GEOTECHNICAL
APPLICATIONS
October 2020

FOREWORD

Published by:

industry.
Document versions:
Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 12: GEOTECHNICAL APPLICATIONS .............................................................................................. 12-1
12.1 PILING ........................................................................................................................................................ 12-1
PART B: LABOUR ENHANCEMENT ............................................................................................................................................................. 12-22
PART C: MEASUREMENT AND PAYMENT ................................................................................................................................................. 12-23
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES .................................................................................................................... 12-30
12.2 GROUND ANCHORS ............................................................................................................................... 12-31

PART A: SPECIFICATIONS .......................................................................................................................................................................... 12-31
12.3 GROUND IMPROVEMENT ...................................................................................................................... 12-52

12.4 LATERAL SUPPORT ............................................................................................................................... 12-86

PART D: GUARANTEES AND COMPLIANCE CERTIFICATES .................................................................................................................. 12-102
12.5 SHOTCRETE .......................................................................................................................................... 12-103

PART A: SPECIFICATIONS ........................................................................................................................................................................ 12-103
PART B: LABOUR ENHANCEMENT ........................................................................................................................................................... 12-112
PART C: MEASUREMENT AND PAYMENT ............................................................................................................................................... 12-113
12.6 MECHANICALLY STABILISED EARTH AND GABIONS ..................................................................... 12-117

12.7 TRENCHLESS METHODS ..................................................................................................................... 12-134

12.8 GROUND DRAINAGE ............................................................................................................................ 12-148

12.9 SLOPE PROTECTION MEASURES ...................................................................................................... 12-162

12.10 HARD EXCAVATION BY BLASTING ................................................................................................. 12-176

12.11 GEOSYNTHETICS............................................................................................................................... 12-191

12.12 CONSTRUCTION DEWATERING ....................................................................................................... 12-198

CHAPTER 12: GEOTECHNICAL APPLICATIONS
12.1 PILING
CONTENTS
A12.1.1 SCOPE
A12.1.2 DEFINITIONS
A12.1.3 GENERAL
A12.1.5 MATERIALS
A12.1.8 WORKMANSHIP

A12.1 PILING
A12.1.1 SCOPE
This Section covers specifications for design, construction and measurement and payment for various pile types for structures and bridges relating
to roads.
A12.1.2 DEFINITIONS
Auger bored piles - are those piles formed in holes bored with an auger drilling rig, with or without use of casing.
Continuous flight auger (CFA) piles - are constructed by drilling in a continuous operation, a CFA auger into the ground and, on reaching
required depth, pumping concrete or grout via a pressurised system, also in a continuous-motion, down the hollow stem as the ground-laden
auger is steadily withdrawn.
Full displacement auger piles - are piles constructed by drilling a displacement auger comprising a lower tapered augered portion of the flight,
a central displacement section and an upper auger section with reverse flighting and, on reaching required depth, pumping concrete or grout down
the hollow stem as the auger is steadily withdrawn.
Underslurry Piles - are piles excavated either by auger or grab-excavation (resulting in circular and rectangular cross-sections, termed barrettes)
under a head of bentonite/polymer slurry to prevent collapse of the pile excavation.
Screwed In Casing Auger Piles (SICAP) - are formed by screwing in a temporary casing and later removing internal material with an auger while
at all times maintaining a plug at the base to prevent water ingress. Twin rotary-drive systems may be used in which casings are installed in a
counter-clockwise direction with one drive head and clockwise-rotating augers with another.
Oscillator bored piles - are piles installed in holes bored by oscillating casings with hydraulic rams into the ground and removing spoil as progress
is made. Casings may be temporary or permanent.
Percussion bored piles - are formed by percussion driving segmental-coupled-casings and excavating soil inside the casing with a coring tool.
On attaining a suitable pile depth, a dry-cast bulbous base is formed. The pile may either be formed by filling the empty bore with high slump
concrete while withdrawing the temporary casing or dry mix concrete is pounded as the casing is withdrawn forming a series of bulbs along the
shaft.
Cast in situ piles (DCIS Piles) - are driven piles installed in holes formed by utilising a drop hammer acting on a sand/stone plug within a tube.
At founding level the plug is expelled from the secured tube. A bulbous base is formed by hammering measured quantities of inserted dry mix
concrete until the theoretically calculated energy required to ensure load capacity, is achieved.
Precast piles - are driven precast reinforced concrete piles generally top driven into the ground using hydraulic or drop hammers displacing in
situ soils. They are cast in any suitable cross-section such as square, hexagonal, rectangular or circular.

Hollow tube steel piles - are driven steel tubes/permanent casings fitted with an end plate or rock shoe which is driven either from top or base
of tube. The pile is sometimes completed by filling the installed tube with concrete and reinforcing steel. Ductile cast iron piles (DIPs) fall into this
category.
Structural Steel Section Piles - or H-piles are driven piles installed either by vibration, drop or hydraulic hammer.
Self-drilling Micropiles - provide a composite load bearing system where continuously threaded hollow bar with a diameter of less 300 mm is
used as load bearing element. They are installed via rotary percussion with simultaneous flushing of the cuttings followed final grout injection
under pressure to fill the annulus between the tendon and the insitu material.
Founding Level - shall mean the underside of the underream, bulbous base or rock socket, the tip of the pile shoe or lower pile end, as may be
relevant
Integrity testing - may comprise cross hole sonic logging and/or sonic tapping.
Cross hole sonic logging (CHSL) - is a test method used to assess quality of installed piles. It involves installing tubes in piles and measuring
velocity and energy dissipation between source and receiver. Sonic tapping test measures frequency response and identifies pile anomalies from
hammer blows at pile head.
Cross hole seismic tomography - involves the measurement of the travel times of seismic ray paths between two or more boreholes in order to
derive an image of seismic velocity in the intervening ground.
Practical refusal - for any driving system, is defined as no more than 25 mm penetration per 20 blows of a hammer operated at maximum
fuel/energy setting, or at an agreed reduced fuel/energy setting based on pile installation stress control.
Ultimate bearing capacity - the ultimate bearing capacity of a pile is the maximum load which it can carry without failure or excessive settlement
of the ground.
Bearing piles - are piles that provide support for vertical loads imposed by structures.
Lateral support piles - are piles that provide lateral support to natural and constructed slopes and excavations.
Soldier Piles - or soldier pile walls are retaining walls with steel piles or reinforced concrete piles spaced at regular intervals. Lagging is placed
between the piles to retain the in situ materials.
Obstructions - are impenetrable objects which may comprise masonry, concrete, reinforced concrete, steel, boulders or other objects requiring
a different method of penetration and construction equipment to that required for soil or soft rock.
Crowd or down force - is the total force applied to the tip of the auger via hydraulics, winching or other means. It may be equivalent to the
operation mass of the machine.
Kelly Bar - is a shaft for extending auger length. It has a spring-loaded cam-action locking dog for transmitting downward force.
A12.1.3 GENERAL
A12.1.3.1 Method Statements
Where so indicated by the Engineer the Contractor shall prepare detailed method statements for each facet of the work describing key aspects
such as construction methodology, key plant, materials, personnel as well as any programme constraints of the envisaged construction process.
These method statements shall be prepared and submitted to the Engineer for approval prior to commencement of that activity, within time scales
specified. The onus lies with the Contractor to ensure that the information is obtained and that associated activities are completed expeditiously
to avoid any delays in the commencement, continuation and completion of the required works. Unless otherwise specified or provided for in the
Contract Documentation no permanent works shall be commenced until the Engineer’s approval of the relevant method statement. The Contractor
shall, however, remain responsible for all work-methods, materials, plant and equipment used, notwithstanding acceptance by the Engineer
Trials, if applicable, shall be conducted and based on outcomes thereof, may require that changes be made to the relevant method statements.
The Contractor shall be required to construct test or trial piles and the testing thereof as specified herein and shall make due allowance therefore
in his programme. Allowance shall also be made for allow for the Engineer’s assessment of constructed piles, procedures followed, and materials
and plant utilised and test data. Production anchoring shall not be permitted until it is shown and accepted by the Engineer that the Contractor
possesses the necessary experience, plant and equipment to carry out the works as specified in the Contract Documentation.
In the case of CFA piles, the following additional information shall be furnished in the Contractor’s method statement:
- Expertise of the design Engineer,
- Design methods used to predict serviceability and ultimate load capacity of the piles and load/deflection performance,
- Experience of site supervisors and operators in the form of CV’s and details of similar projects completed.
- Equipment for pile installation, including anticipated pressures at pump and auger toe and,
- Instrumentation for monitoring pile installation.
It should be noted that work shall only be performed by personnel listed by the Contractor. If personnel changes need to be made during the
project, works shall be suspended until replacement personnel are approved by the Engineer. Time lost due to incomplete submissions,
unacceptable submissions, or obtaining approval of replacement personnel will not be considered as cause for extension of time or delay claims.
All costs associated with incomplete, replacement, or unacceptable submissions shall be to the Contractor’s cost.
Once approved in writing by the Engineer, these shall become the method statements in accordance whereby the relevant portion of the works
shall henceforth be executed. Notwithstanding, the Engineer may require revision from time to time if circumstances during construction arise
which warrants change.
A12.1.3.2 Materials and materials design

All materials used in the works described hereunder shall meet the appropriate standards given below and/or specified in the Contract
Documentation and shall be subject to the approval of the Engineer. The Contractor shall submit product certificates, conformance documentation

related to the specifications as detailed in Part D, test results as required together with samples of materials and, where applicable, materials
designs that he proposes to use in the construction of the works to the Engineer for his acceptance/approval as provided for in the Contract
Documentation.
Due allowance shall be made for obtaining materials, resubmissions and re-designs, all to the required/approved standards, methods and practices
in attending to these requirements. Particular attention shall be paid to the early submission of materials-, concrete- and grout mix designs where
parameters at various ages may be specified. No consideration for extension of the contract period will be entertained for delays incurred in
meeting these requirements.
Particular attention is drawn to the approvals required as indicated in Table A12.1.3-1 below regarding works carried out under this section of the
works:
Table A12.1.3-1: Required approvals
Clause Requirements* Period
Design Approvals
A12.1.3.5 Alternative Designs for Piling and Piling Layouts 5 weeks prior to commencement of
piling
A12.1.3.5 (b) Alternative Piling Design Approvals 3 weeks prior to commencement of
piling
A12.1.3.1 Materials Design Approvals
A12.1.4.1 Mix design for concrete/grout for piles 6 weeks prior to commencement of
placement
A12.1.7.1
A12.1.4.1 Grout / concrete mix design for CFA pile / micropile construction 6 weeks prior to commencement of
placement
A12.1.4.2
A12.1.7.1
Materials/ Equipment Approvals
A12.1.6.1 Piling equipment details 3 weeks prior to commencement of any

piling
A12.1.7.2
Construction Approvals
A12.1.6.2 Contractor’s method statement for test piles 3 weeks prior to commencement of test
piles
Load testing of piles and review of results 5 weeks after test pile installation
A12.1.7.7b) Contractor’s approved method statement for piling prior to commencement of production
piling
A12.1.7.8a) Details of design and pile driving criteria for precast piles 3 weeks prior to commencement of
piling
A12.1.7.7a) Contractor to notify Engineer when obstructions are encountered Within 24 hours of stoppage
A12.1.3.3 General aspects

This section covers piles constructed of concrete or steel or a combination thereof.
If during the course of installing piles it is found that soil or founding conditions differ greatly from those described in the documentation or shown
on the drawings, the Contractor shall immediately notify the Engineer.
The Engineer shall, as often as he deems necessary, instruct the Contractor to conduct additional foundation investigatory work and/or tests at or
below respective founding levels with a view to establish safe bearing pressures and founding depths.
A12.1.3.4 Pile type and piling layout

Pile type, layout, minimum size, steel reinforcement and concrete class required, shall be as detailed and specified on the drawings and project
specifications unless otherwise specified in the Contract Documentation.
A12.1.3.5 Alternative designs for piling and piling layouts

The following shall be applied where alternative designs for piling and piling layouts are submitted by tenderers if acceptable in terms of the tender.
It should be noted that in some cases alternatives are NOT permitted.
a) Submission
A priced schedule of quantities submitted for alternative designs shall be compiled strictly in accordance with the contract with relevant
measurement and payment Clauses of these specifications. Where pay items defined in these specifications are omitted, it shall mean either:

- Items do not apply, or
- Where the Engineer requires work falling under such items to be done, it shall be done without any cost to the Employer.
- Inclusion of "rate-only" items is not permitted.
Where pay items not defined in these specifications are used, measurement and payment requirements for such items shall be specified in detail
by the Contractor. Absence of such definitions, or in the case of any ambiguity, interpretation of the Engineer shall be final and binding.
Except in piling-only contracts or where otherwise provided in the Contract Documentation, the Contractor shall price the schedule of quantities
for the original design in the tender, irrespective of whether an alternative design is offered.
b) Design
Critical design-load combinations acting on underside and centre-of-gravity of pile-capping slab, maximum permissible set of pile-capping slab,
and technical data required for designing alternative piles and/or piling layouts will be indicated on drawings. Alternative designs shall comply with
the provisions of Clause A1.2.4.1 of Chapter 1 and prescriptions set out below.
For submitted alternative designs, the Contractor shall submit with his tender a detailed description of method of analysis used in design of piles
and the pile-group layouts. Average length of pile and/or piles per group, on which quantities in the schedule for alternative designs are based,
shall be stated in each case. The type of pile offered shall be defined in terms of size, materials, working and ultimate load.
Consideration shall also be given to any bulk earthworks, which may affect length and downdrag on piles.
The Contractor shall be responsible for cost of redesigning, drafting and submitting detail drawings for any structural element affected by the
alternative pile design as well as the cost of the review of the alternative design/s by the Engineer. Any economy or incidental caused by
constructing such element compared to the original design, shall be for the Contractor’s account.
No piling work for which an alternative is offered shall commence unless approved by the Engineer, in writing. After approval, no departure there-
from shall be made without Engineer-authorisation. Final working drawings shall comply with the provisions of Clause A1.2.4.1 of Chapter 1.
Where alternative piles fail during load testing as specified in Clause A12.1.8.4, the Contractor shall be responsible for the cost of work required
for rectifying piles and pile layout so as to comply with design requirements.
c) Basis of payment
Where quantities in the schedule of quantities referred to in Clause A12.1.3.5a) on the one part, differ from the number of piles and average pile
length given in the submission for alternative pile design, on the other part, the Engineer shall accept the sum in the said schedule of quantities,
correct the quantities, and adjust the rates for the applicable pay items accordingly.
In addition to these corrections, the Employer shall be justified in using one of the following methods for paying for piles constructed in accordance
with alternative designs
(i) Method 1
The Employer shall check alternative designs, calculate quantities and adjust rates as set out in paragraph 1 of Clause A12.1.3.5
c). The Employer will then pay for work in accordance with actually-measured quantities.
(ii) Method 2
The Employer may use the following formulae for calculating quantities under items C12.1.4 to C12.1.23 for payment:
Np = Nd
Lp = Nd . Ld + Nb(Lb-Ld)K for Nd  Nb and
Lp = Nd . Ld + Nd(Lb-Ld)K for Nd  Nb
K=Lb/Ld for Ld≥Lb and
K=Ld/Lb for Ld≤Lb
where:
p = paid, d = designed and b = built.
The term "units" means items of work measured and paid for under respective pay items such as piles, raking piles, casings,
under-reams, concrete, etc.
Np = number of "units" measured and finally paid for in a particular pile group.
Nd = number of "units" provided for in the tender for the alternative design in the same pile group.
Nb = number of approved and accepted "units" finally installed in the same pile group.
p = the length of the "units" measured and paid for or the length to be used in calculating quantities which are a direct function of
the length of the "units" for the same pile group.
Ld = the average length of the "units" provided for in the tender for the alternative design in the same pile group.
Lb = the average length of the Nb "units" actually installed in the same pile group.
Note: See the example below for application of formulas
The values Nd and Ld for each pile group for which an alternative design was offered shall be supplied with his tender by the
Contractor for the respective "units".
The values of Nd, Nb, Ld and Lb for each pile group for which are to be used in the formulae for determining the quantity for a
particular pay item shall relate only to the piles where the item is measured.

Table A12.1.3-2: Measurement for payment for alternative piles in accordance with Clause A12.1.3.5c)
CRITERIA
Nd  Nb Lb Nd  Nb
K = Ld for Ld > Lb
Np = Nd Np = Nd
Ld
K = Lb for Ld < Lb
Lp = Nd.Ld + Nb(Lb - Ld)K Lp = Nd.Ld + Nd(Lb - Ld)K
Table A12.1.3-3: Example for measurement for payment of alternative piles

Nd > Nb Nd = Nb Nd < Nb
1.1 Nd = 30 Ld = 12 1.2 Nd = 25 Ld = 12 1.3 Nd = 20 Ld = 12
Nb = 25 Lb = 10 Nb = 25 Lb = 10 Nb = 25 Lb = 10
Ld > Lb
10 10 10
Lp = 360 + 25(-2) 12 = 318 Lp = 300 + 25(-2) 12 = 258 Lp = 240 + 20(-2) 12 = 207
No Length No Length No Length
Offered 30 360 Offered 25 300 Offered 20 240

Built 25 250 Built 25 250 Built 25 250
Paid 30 318 Paid 25 258 Paid 20 207
2.1 Nd = 30 Ld = 10 2.2 Nd = 25 Ld = 10 2.3 Nd = 20 Ld = 10
Nb = 25 Lb = 10 Nb = 25 Lb = 10 Nb = 25 Lb = 10
Ld = Lb Lp = 300 Lp = 250 Lp = 200

Paid 30 300 Paid 25 250 Paid 20 200
3.1 Nd = 30 Ld = 8 3.2 Nd = 25 Ld = 8 3.3 Nd = 20 Ld = 8
Nb = 25 Lb = 10 Nb = 25 Lb = 10 Nb = 25 Lb = 10
Ld < Lb
8 8 8
Lp = 240 + 25(2) 10 = 280 Lp = 200 + 25(2) 10 = 240 Lp = 160 + 20(2) 10 = 192

Paid 30 280 Paid 25 240 Paid 20 192
A12.1.3.6 Piling platforms

Piling platforms shall include re-working and strengthening of in situ material or artificial islands or any structure (excluding piling equipment)
constructed for gaining access to the positions where piles are to be installed and piling operations carried out. An adequate margin of safety is
required on bearing capacity and settlement to ensure system reliability during construction without any detrimental affect to the permanent works.
The Contractor may, at his own risk, use any material deemed suitable by him for constructing islands, but he shall note that no separate payment
shall be made in terms of item C13.1.3.2 (Excavations) of Chapter 13, items C12.1.6, C12.1.8 and C12.1.9 as well as item C13.1.30 (Caissons)
of Chapter 13, for any obstructions or hard inclusions occurring in material used for constructing temporary banks or artificial islands.
Design and construction of cofferdams shall comply with BS 8004. Before starting construction, the Contractor shall submit drawings indicating
details of cofferdams and methods of construction to the Engineer.
Structural piling platforms shall be rigid, and floating barges used for piling operations shall afford sufficient stability to enable the piles to be
properly installed without any risk to neighbouring facilities or personnel
On completion of piling, the Contractor shall remove all artificial, constructed platforms and reinstate the site to the satisfaction of the Engineer.

A12.1.4.1 General
The Contractor shall design the concrete and/or grout used for the construction of all concrete piles in accordance with the requirements given
in Clause A12.1.5 below and Section A13.4 of Chapter 13. Mix designs shall be complete, be presented on the required forms and shall be
presented to the Engineer with samples of all the constituents as required at least 6 weeks prior to placement
A12.1.4.2 CFA Piling and Self-Drilling Micropiles

The grout and concrete mix design for CFA piles and Self-drilling Micropile construction shall be given special attention to ensure the desired
fluidity, compaction under self-weight, resistance to segregation, controlled set times are achieved, and all solids remain in suspension in
grout/concrete without excessive bleed-water. Submitted mix designs shall include curves of viscosity loss versus time to ensure acceptable fluid-
consistency for greater than 2 hours, such that the reinforcement may be inserted.

A12.1.5 MATERIALS
A12.1.5.1 General
All materials used in constructing of piles shall comply with the requirements given in these specifications. When requested by the Engineer, the
Contractor shall submit test certificates from an approved independent testing authority to show that the materials comply with specified
requirements, or where applicable certificates from patent holders or licensees certifying that manufactured items comply in all respects with the
relevant product specifications.
A12.1.5.2 Concrete and grout

The Contractor shall be responsible for the design of the concrete mix/grout mix used to form piles. It shall be so proportioned as to be of sufficient
strength and workability to enable properly placement, and, where self-compacting concrete is not used, it shall be thoroughly compacted by
approved means.
The relevant requirements of Clause A13.4 of Chapter 13 shall apply in respect of concrete or grout for piles. Unless otherwise specified in the
Contract Documentation all concrete used for piles shall be Prescribed composition (Class P) concrete in accordance with Clause A13.4.7.8 of
Chapter 13 where aggressive water (or soil) is anticipated, or Durable (Class D) concrete in accordance with Clause A13.4.7.7 of Chapter 13 for
all other applications.
All concrete shall be categorised in the compressive strength classes as shown in Table A13.4.7-15 in Chapter 13.
Class D concrete mix shall meet the following criteria:
a) the specified 28-day characteristic cylinder or cube compressive strength;
b) the specified 28-day nominal oxygen permeability index;
c) the specified 28-day nominal chloride conductivity value; or
d) a characteristic 28-day cylinder or cube compressive strength corresponding to the maximum water: cementitious binder ratio for chloride (XS)
environments.
For Class P concrete, the characteristic strength of the mix shall be based on the higher of the following values:
a) the specified 28-day characteristic cylinder or cube compressive strength;
b) a characteristic 28-day cylinder or cube compressive strength corresponding to the maximum water: cementitious binder ratio;
c) a characteristic 28-day cylinder or cube compressive strength corresponding to the minimum cementitious binder content; or
d) a 28-day characteristic cylinder or cube compressive strength corresponding to the maximum water content.
The fluidity and of each grout batch mixed shall also be measured with a flow cone in accordance with Clause A 13.5.5.9 of Chapter 13 and, if
specified, with a viscometer. For stiffer grouts and grouts with fine aggregate as for CFA piling applications a modified CRD flow cone with an
enlarged (up to 19 mm diameter) orifice complying with ASTM1939 is used. Any variation exceeding 20 % of the average daily recorded values
shall be immediately brought to the attention of the Engineer.
The grout and concrete mix design for CFA piles and Self-drilling Micropile construction shall be given special attention (where applicable) to
ensure desired fluidity, compaction under self-weight, resistance to segregation, controlled set times are achieved, and all solids remain in
suspension in grout/concrete without excessive bleed-water. Submitted mix designs for CFA piling shall include curves of viscosity loss versus
time to ensure acceptable fluid-consistency for greater than 2 hours, such that the reinforcement may be inserted.
Grout and cement for self-drilling micropiles shall comply with SANS 54199:2017 and normative reference EN 206:2013 which has been adopted
as SANS 50206:2015 (Concrete - Specification, performance, production and conformity).
Water for concrete and for grout for micropiles shall comply with SANS 51008.
A12.1.5.3 Aggregate
Aggregates shall comply with SANS 1083.
A12.1.5.4 Cementitious binder

Cement and supplementary cementious binders shall comply the requirements with Clause A13.4.5.1 in Chapter 13. The use of additives shall
be subject to the Engineer’s approval and demonstrated performance.
A12.1.5.5 Bentonite slurry

Bentonite slurry for underslurry piles shall consist of approximately 5 % of sodium bentonite powder by mass with water and be of such consistency
that soil and other heavy particles mixed with this bentonite slurry during excavation are held in suspension and do not settle to the pile base.
Water for bentonite slurry manufacture grout shall comply with SANS 51008.
A12.1.5.6 Reinforcing steel

Steel reinforcing bars shall comply with the requirements of SANS 920. For each consignment of steel reinforcement delivered to the site, the
Contractor shall submit a certificate issued by a recognised testing authority confirming that the steel complies with the specified requirements.
Cold-worked reinforcing bars shall not be used. The type of bar required shall be indicated on the drawings by the symbols R, Y or Z in accordance
with SANS 282.
A12.1.5.7 Self-Drilling Micropiles

Steel for the manufacture of self-drilling micropiles shall comply with EN 10210.
Steel for load bearing elements of a self-drilling micropile shall comply with EN 10210 (Hot finished structural hollow sections of non-alloy and fine
grain structural steels). A fine grained construction steel with a minimum grade S460NH shall be used to ensure that the load bearing elements
remain intact after installation.
Self-drilling micropiles require a minimum Charpy V-notch impact energy of 40 Joules at -20℃ tested in accordance with BS EN 100451-1:1990
to withstand the installation process using rotary percussion.
The corrosion protection of the self-drilling anchor shall take into account the surface geometry of the bar, the tensile stresses of the steel and
corresponding crack widths of the grout body.

Connecting elements shall not compromise the required capacity of the load bearing elements.
A12.1.5.8 Mechanical joints for precast piles

These joints shall be cast and later machined and be of sufficient quality to transfer during static and dynamic loading, axial compression, tension,
shear force and bending moment in the pile without overstressing any component of joint, splice bars and surrounding concrete.
Joints shall have faces at right angles to the pile longitudinal axis to ensure jointed shafts exhibit one common longitudinal axis. To achieve this,
the joints must have devices for accurate location in shutter when casting concrete.
A12.1.5.9 Rock shoes

Precast pile-tip rock shoes, shall be of sufficient quality to enable the penetration of cobbles, boulders, or hard rock on level or sloping surfaces.
A12.1.5.10 Steel tubes

Tubes shall comply with SANS 719 Grade B with wall thickness as specified in the Contract Documentation. Splicing bands shall be approximately
250 mm wide and shall be manufactured from plate with same thickness as tube.
Lead sections of tubes shall have a steel plate or rock shoe welded to toe-end with a splicing band welded to top end.
Ductile iron piles (DIPs) are manufactured from cast iron which has had magnesium graphite flakes added. The annealing process in the
manufacturing creates a very thick, high corrosion-protection layer. Pipes shall have a tapered socket with an internal shoulder for full engagement
at the top and a tapered spigot at the bottom facilitating individual pile section connection to enable piles of any length.
The material properties of ductile cast iron are given in Table A12.1.5-1 below.
Table A12.1.5-1: Ductile cast iron material properties
Tensile Strength 420MPa
Yield Strength 320MPa
Compressive Strength 900MPa
Modulus of Elasticity 170 000MPa
A12.1.5.11 Steel sections

Steel H-sections shall comply with SANS 50025 / EN 10025:2004. Where so indicated shear transfer cleats or lugs shall be welded to the head
of the pile to ensure the transfer of load from the pile cap into the pile.
A12.1.5.12 Casing
Temporary casings shall be sufficiently thick and rigid so as accommodate piling rig torque and to not deform under the collapse of adjacent soil
prior to concreting or while being extracted during concreting. Where casings may require jacking via hydraulic rams from depth, double wall
casings shall be used.
Permanent casings are usually corrugated steel galvanised liners or steel casings, 4,5 mm or thicker with a nominal ID as specified.

A12.1.6.1 General
It is the Contractor’s responsibility to carefully scrutinise soil profiles given in geotechnical reports in conjunction with borehole cores to satisfy
himself that the pile rigs he intends to use on site are capable of penetrating the in situ soil/rock types to the depths indicated in the Contract
Documentation. The Contractor shall provide full details of all the equipment he intends to use in his method statement for pile installation as
detailed in Clause A12.1.7.2
A12.1.6.2 Installation equipment

Piles are generally installed using crane-supported pile installation frames, hydraulic drilling rigs or oscillators.
Selected or specified installation equipment shall be appropriate for the required pile installations and in good working order subject to approval
of the Engineer and shall comply with relevant legal provisions. Such shall also be capable of installing piles to the specified depths, in the required
positions true to line and rake.
Rated capacity, boom lengths, torque, rotational speed, crowd and power of hydraulic units used to turn augers, casing or other piling tools shall
be appropriate to the specified /approved piling method and product.
Where so specified in Contract Documentation, installation drill rigs shall contain computer-controlled monitoring and control systems. This
equipment shall have capability to monitor and record the following:
- Auger rotation,
- Volume of grout or concrete,
- Depth of auger-injection point,
- Maximum and minimum grout or concrete pressure
- Torque delivered to auger, and
- Crowd (downward thrust on auger)
- Rate of penetration/withdrawal.
The above shall be detailed in a method statement.

All measurements should be referenced to (or plotted against) depth of auger injection point. Generally, this requires a rotational position indicator
on the auger head system and an electronic position indicator on the crane line or boom/frame holding the auger. Torque and thrust load cells
shall be positioned on the auger head systems, and electronic flow meters and pressure transducers placed in the grout/concrete pressure lines.
All monitoring equipment shall be calibrated at the project commencement in accordance with the equipment manufacturer’s specifications.
A12.1.6.3 Grout/concrete pumps

The size and capacity of grout/concrete pumps utilised in piling shall be compatible with size of pile being constructed to ensure a smooth,
continuous delivery of grout or concrete is maintained. For CFA piles, grout/cement pumps shall be a positive-displacement capable of developing
pressures at pump of 2.4MPa verified by the instrumentation. Grout/concrete volumes are determined from stroke count or in-line flowmeters and
pressures by in-line sensors and cab-mounted instruments for informing operators. Records are required for quality control purposes and quantity
measurement.
A12.1.6.4 Equipment for underslurry piles

Bentonite slurry for underslurry piles or barrettes shall be mixed on site in a suitable mixing plant and stored in holding tanks with sufficient capacity
for continuance of the works. Bentonite slurry is fed to pile excavation during drilling operations and pumped back to storage tanks during
concreting. In the course of operations, slurry becomes intermixed with in situ material. This shall be removed before further use, utilising cyclones
and vibrating sieves or similar suitable equipment. All equipment shall be in good working order and shall be approved by the Engineer.
A12.1.6.5 Equipment for displacement auger piles

Piling rigs used to install displacement auger piles shall be fitted with high-torque rotation heads and shall have a crowd and removal capability
for hollow-stem auger pile flights for the successful execution of the works. Displacement auger tools shall be designed to ensure full displacement
during downward pushing and rotation of the tool. This tool shall generally comprise a lower tapered augered portion of the flight, a central
displacement section, and an upper auger section with reverse flighting.
Hollow-stem flights shall be blocked off at toe with a suitable plug prior to the flight being lowered into position. The flight shall be rotated and
simultaneously pushed to penetrate the soil. Rate of penetration, torque and crowd shall be fully recorded on the rig's data capturing system.
Installation energy shall be calibrated against trial pile test data to ensure satisfactory pile load capacity during installation.
All equipment shall be in good working order and shall be approved by the Engineer.
A12.1.6.6 Equipment for Screwed-in Casing Auger Piles (SICAP)

Two systems are commonly used. A simple application involves the fitting of a bar to the auger flight t of the drill rig which is used to screw in the
casings. On reaching the capacity of the machine, the bar is removed and the auger is used for the internal removal of material leaving a plug at
base to prevent water ingress. The process is repeated until the desired depth is reached (usually on bed rock).
In more sophisticated systems, the drill rig is fitted with two independent superimposed rotary heads rotating in opposite directions to
simultaneously screw in casing and auger in opposite directions. Casings are usually screwed in counter-clockwise with the auger using a
clockwise rotation. The bottom of the auger is fitted with a sealing flap to prevent infiltration of water and/or soil into the central axis of the hollow
auger during screw-in phase.
The Contractor shall provide evidence that the proposed equipment is appropriate for the pile type and is in good working order for approval by
the Engineer.
A12.1.6.7 Equipment for Oscillator Bored Piles (OBP)

Oscillators used for installation of these piles shall be equipped with a pile-casing clamp for rotational movement through 15-20° and hydraulic
rams for lowering and raising of the casing. Casings are temporary with a possible permanent liner (inner casing) of specified material thickness
and nominal internal diameter (ID). Supporting cranes shall be equipped with various excavation tools required for removal of spoil from pile-bore
and for supporting tools and chisels for rock-sockets.
the Engineer
A12.1.6.8 Equipment for Percussion Bored Piles (PBP)

Equipment used for installation of these piles generally consists of a tripod type mast with a winch and engine mounted on a frame fixed to one of
the legs of the tripod. The system uses temporary piling tubes manufactured in 1m lengths with screw-coupled sections. Various excavation tools
are used for spoil-removal from pile- bore and tube-driving. An internal drop hammer is used for forming enlarged bases and a separate hydraulic
jacking unit for tube extraction.
the Engineer.
A12.1.6.9 Equipment for Continuous Flight Auger (CFA) Piles

Rigs shall have adequate torque capacity to install the piles without flighting or undermining of the soil during drilling.
Auger flights for CFA piles shall be continuous from the top to the cutting-face tip, with no significant gaps or other breaks. Gaps less than 25 mm
in flights, may only be present where auger sections are joined.
The length of any auger brought to site shall be such that it is capable of installing a pile to a depth 20 % greater than the depth of the pile shown
on the approved working drawings. Auger flighting shall be of uniform diameter, bend and damage-free throughout its length, with an outside
diameter greater than 97 % of the design-diameter. Only single helix augers shall be used.
the Engineer

A12.1.6.10 Equipment for Self-drilling Micropiles
a) General drilling equipment
The drill rig and equipment shall be in good working order and capable of producing the anchor/bolt or soil nail hole to the required dimensions,
tolerances, direction, torques, blow impulse, blow energy and inclination without undue disturbance of the surrounding material. Should the type
of rig and/or equipment prove inappropriate for the requirements or conditions on site, these shall be replaced by suitable equipment at the
Contractor’s cost. The drill rig/equipment shall be able to install and remove casings as required during drilling operations, without loss of direction
or inclination, in all materials.
b) Grout mixer
The mixer used for the manufacture of grout for anchoring purposes shall be a high shear colloidal mixer. The holding tank shall be fitted with an
agitator capable of maintaining the colloidal condition and fluidity of the mix. The outlet shall be fitted with a suitable filter with openings of less
than 1,0 mm to remove any aggregations larger than 4,0 mm.
c) Grout pump
The grout pump shall be a positive-displacement type and shall, unless otherwise specified, be capable of exerting a constant pressure of up to
100bar or as may be required for high pressure grouting. The pump shall be fitted with a currently calibrated pressure gauge with a dial of a
suitable diameter enabling accurate readings to the nearest bar and a valve which can be locked-off without pressure loss. The hoses used shall
be appropriately rated for the pressures required. The grout volume flow shall range between 35l/min and 120l/min, depending on the size of self-
drilling micropiles to be installed.
A12.1.6.11 Equipment for Driven Cast In Situ Piles (DCIS)

Rigs for installing DCIS piles have an engine, a winch, a mast, an open-ended piling tube and a long cylindrical drop-hammer which is located
within the tube-bore, the latter held and guided by the mast.
the Engineer.
A12.1.6.12 Equipment for precast-, steel tube- or sectional steel piles

Piles shall be driven with gravity or hydraulic hammers or other approved means.
Precast concrete piles shall be driven with a hammer of mass greater than the pile mass. Other piles shall preferably be driven by a hammer with
similar mass characteristics. Piles shall be supported in line and position with leaders while being driven.
Pile driving leaders shall be constructed to afford freedom of movement of the hammer and held in position to ensure adequate support for the
pile or pile casing during installation. Inclined leaders are used for installing raked piles.
Heads of concrete piles shall each be protected by a pile cushion of cross-sectional area similar to the pile top. Pile cushions shall be made of
plywood, hardwood, or composite plywood and hardwood materials sometimes augmented by multiple paper layers. Pile cushion thickness shall
be greater than 100 mm.
Piles driven with impact hammers shall have adequate helmets or drive-heads to distribute the hammer force to the pile head and prevent damage
to any permanent component of the pile. Helmets shall be axially aligned with the hammer and the pile to prevent eccentric or torsional impact and
be guided by non-free swinging leaders.
Pile shoes as detailed/specified in the Contract Documentation shall be used.
H-pile shoes composed of steel plates welded to flanges and webs do not provide protection or increased strength at the critical flange to web
connection and shall not be used unless otherwise approved by the Engineer.
Followers shall only be used if approved. The follower and pile shall be held and maintained in equal and proper alignment during driving.
the Engineer.
A12.1.6.13 Equipment for Ductile Iron Piles (DIPs)

Driven ductile cast iron piles utilises high strength ductile iron pipes manufactured using a spun-cast process. Outside diameters are generally
118 and 170 mm and standard pile lengths are 5.0m.
Ductile iron pile systems consist of a tapered socket as the lead end of a 5,0 m pile with the drive end being a tapered spigot. This joint system
develops full capacity of the pile shaft with a high degree of axial and bending stiffness.
The lead pile section is fitted with an appropriate pile driving shoe. For friction piles this is a conical grout point and for end bearing piles it a
standard driving shoe or end plug. In normal unobstructed soils a flat shoe is used to form an end plug. For soils that contain obstructions that
are to be penetrated a steel end plug with a rock point is used. Piles may be driven open-ended. When driven in this manner, some 1,5 m of the
lead section fills with soil during driving, sealing the pile against water and soil infiltration.
For friction grouted piles a conical grout shoe is fitted to the lead section. These grout shoes are available in 220, 270, 320- and 370-mm diameter.
The 220 mm grout shoe can be used only with 118 mm diameter piles while 270, 320- and 370-mm shoes can be used with either 118 or 170 mm
diameter piles.
the Engineer.
A12.1.6.14 Equipment for rotary core drilling

The drill rig and equipment shall be in good working order and capable of producing the required hole to the required dimensions, tolerances,
direction and inclination and core recovery without undue disturbance of the surrounding material. Should the type of rig and/or equipment prove
inappropriate for the requirements or conditions on site, these shall be replaced by suitable equipment at the Contractor’s cost. The drill
rig/equipment shall be able to install and remove casings as may be required during drilling operations, without loss of direction or inclination, in
all materials.

A12.1.7.1 Test piles
Where provided for in Contract Documentation, the Contractor shall install test piles at positions commensurate with production piles.
Test piles shall be installed to the same dimensions, using the same methods, personnel, plant, equipment and materials envisaged for production
piles.
It should be noted that concrete and grout mix design proposals are required to be submitted to the Engineer for approval 6 weeks prior to
placement.
A method statement describing every facet of installation shall be presented to the Engineer for his approval 3 weeks prior to commencement of
test piles.
Test piles shall be subject to testing. The installation shall be witnessed by the Engineer or his representative and the operation shall be fully
documented. The results shall provide the required installation parameters and procedures for compiling the method statements for the production
piles. Production piling shall not commence until the Engineer has assessed the results.
Test piles shall be paid for as for production piles, if applicable.
A12.1.7.2 Construction Method Statements

Production piling shall not commence until required method statements, materials designs and other requirements as specified are received and
approved, in writing, by the Engineer.
Due allowance shall be made for the installation, curing, testing and result assessment by the Engineer. Changes or deviations from approved
method statements shall require re-submittal for approval. No claims in respect of standing time or extension of time will be considered in this
regard.
The following shall be addressed as appropriate:
- List and sizes of proposed equipment, including drilling rigs, augers, pile driving equipment and other drilling tools, pumps for grout or
concrete, mixing equipment, automated monitoring equipment, and similar equipment to be used in construction, including details of
procedures for calibrating equipment as required,
- Step-by-step description of pile installation procedures,
- A plan of pile installation sequence,
- Target drilling parameters (along with acceptable ranges) for pile installation, including rotation speed, drilling penetration rates, torque and,
applied crowd pressures, grout pressures, and grout volume factors,
- Target driving resistance or set for driven piles
- Target concreting and grouting parameters (along with acceptable ranges) for pile installation, including grout pressures, and concrete and
grout volume factors,
- Details of methods of reinforcement placement, including support for reinforcing cages at pile-top and methods for centering cages within
the grout or concrete column,
- Mix designs for all grout or concrete used on the project, including slump loss vs. time curves and strength development vs. time curves for
mixes with fly ash and/or slag,
- Equipment and procedures for monitoring and recording auger rotation speed, penetration rates, depths, and crowd pressures during
installation,
- Equipment and procedures for monitoring and recording grout or concrete pressures and volumes placed during installation where applicable,
- Contingency plans for equipment failures during drilling, grouting or concreting operations (grout pump, monitoring equipment, etc.),
- Procedures for protecting adjacent structures that may be adversely affected by foundation construction operations, including a monitoring
plan.
A12.1.7.3 Setting out

It is the Contractor’s responsibility to set out pile positions and he shall stake these positions with an approved, durable marker system. Where
levels from which the piling is undertaken is above the underside of the pile-cap, due allowance shall be made for offset of raking piles so that the
piles shall be in correct position.
A12.1.7.4 Ground surface for foundation piling

Before starting any piling work, the Contractor shall notify the Engineer in good time to ensure that levels of the ground surface be taken in order
that an average ground surface from which the piling is to be measured can be established and agreed. Where foundation piling at a site is
preceded by excavation or construction of fill, the surface from which the piling is to be conducted shall be formed as near as possible to the
underside of pile-cap slab as directed by the Engineer.
Where provided for in the Contract Documentation, payment will be made for the provision of lateral support to excavations under pay item
C12.1.31. The cost of excavating the material shall not be included but paid for under items C13.1.3 and C13.1.4 of Chapter 13.

Unless otherwise specified in the Contract Documentation the tolerances given in Clause A12.1.8.1 are the maximum permissible deviations from
specified dimensions, levels, alignment, positions, etc, shown on the drawings for structures or structural members.
Any pile outside of these tolerances shall be subject to review by the Engineer and may be rejected and replaced at the Contractor’s expense.

A12.1.7.6 Piling materials
Piling materials are those materials (or horizons or subsoils or substrata) that are penetrated during the course of the pile installation.
These materials are categorised as identified materials, unidentified materials and obstructions.
Identified materials are defined as those subsurface materials that were identified during the Engineer’s investigations and are described in the
Contract Documentation and drawings and for which provision is made in respect of penetrating such materials. Borehole core, borehole logs and
profiles are generally included in the documentation. Borehole cores, if applicable, are available for inspection.
Unidentified materials are materials encountered during boring and/or driving of piles that were not identified and described in Contract
Documentation and which presence was not foreseen and for which penetration rate drops more than that provided for in Contract Documentation
when the same method and effort are used or subject to additional methods and effort over and above those required for penetrating identified
materials being necessary for penetrating the materials. If unidentified materials are encountered which do not allow pile-completion at a planned
location, the Contractor shall notify the Engineer and designer within 24 hours for remedial action.
Obstructions are man-made features which may comprise masonry work, concrete, reinforced concrete or other objects requiring a different
method of penetration and which may require ancillary works such as cavity grouting to stabilise areas after penetration/removal of obstructions.
Where obstructions are encountered which do not allow pile-completion at a planned location, the Contractor shall notify the Engineer within 24
hours for remedial action.
The following classification of materials shall apply to identification and description of identified, unidentified materials and obstructions:
- Matrix shall comprise that part of the material which will pass through a sieve with 50 mm x 50 mm openings.
- Coarse gravel shall comprise that part of material (stones, pebbles, cobbles, etc) which will pass through a 200 mm x 200 mm opening but
will not pass through a 50 mm x 50 mm opening. Gravel shall be obtained from material with greater than R2 hardness as per Table A12.1.7-
1.
- Boulders shall mean any rock mass with hardness of at least class R2 which will pass through a square opening with dimensions equal to
the maximum size boulder specified in the Contract Documentation but will not pass through a 200 mm x 200 mm opening.
- Rock formation shall be any rock mass with hardness greater than R2 which will not pass through a square opening with dimensions equal
to the maximum size boulder specified in the Contract Documentation.
Where a boulder is cut through and part of it is left imbedded in the wall of the pile hole, such boulder material shall be classified as rock formation.
For identification of rock in terms of this Clause, classification given in Table A12.1.7-1 shall apply.
Table A12.1.7-1: Rock hardness classification
Unconfined/
Uniaxial
HARDNESS*
compressive
strength (MPa)
Class Description Field indicator tests
R2 Soft rock Can just be scraped and peeled with a knife, firm blows of pick point leave 3 to 10
indentations 2 mm to 4 mm in specimens.
R3 Medium hard Cannot be scraped or peeled with a knife; hand-held specimen can be 10 to 25
rock broken with hammer end of a geological pick with a single firm blow.
R4 Hard rock Point load tests on recovered borehole core shall be used for distinguishing 25 to 70
between these categories.
These results shall be verified by means of uniaxial/unconfined
R5 Very hard rock compressive-strength tests conducted on samples which have a diameter Greater than 70
of between 50mm and 150mm with lengths greater tan 100mm and which
meet the requirements set out in the Note below.
NOTE: The equipment used shall have a valid calibration certificate and the tests shall be carried out by an approved competent person. Sample
orientation in testing shall be similar to that in penetrating the tested material during piling. Standing time shall not be paid while the results of tests
are awaited.
* Classification after Core Logging Committee, South African Section, Association of Engineering Geologists:
" Guidelines for Soil and Rock Logging in South Africa, 2nd Impression 2002, eds. A.B.A. Brink and R.M.H. Bruin, Proceedings, Geoterminology
Workshop organised by AEG, SAICE and SAIEG, 1990.
A12.1.7.7 Cast in situ concrete piles

a) General
These include piles installed by rotary drilling (including auger drilling), percussion drilling and oscillator boring.
Where lateral support piles are specified, any widening to capping beams or structural elements constructed on top of the piles resultant from
misalignment of piles, shall be to the Contractor’s account. Such remedial actions shall be to the Engineer’s approval and shall take cognisance
of both Engineering and aesthetic considerations.

b) Formation of holes for piles
Holes for piles shall be formed using plant and equipment appropriate for type of pile to be constructed and materials through which holes are to
be formed. The Contractor shall perform drilling through whatever materials are encountered, to dimensions and elevations given in approved
designs and as shown on approved working drawings.
Augering and boring of pile holes shall be carried out as expeditiously as local conditions permit taking due account of services or other restrictions
on site. Spoil shall continuously be removed from the drilling platform to an approved temporary or permanent site. The Contractor shall be liable
for any delays or consequential damages of any kind resulting from his failure to immediately remove piling spoil from piling platforms. The area
surrounding the holes shall be cleaned after augering and boring to obtain a clean, level surface. Surface water shall not be allowed to enter the
hole.
Where indicated by the Engineer, suitable casing shall be installed in those parts of augered holes where potential side collapse may occur, before
concreting is completed. During extraction of casings, care shall be taken to avoid lifting placed concrete with concomitant damage to the pile.
Concreting can be carried out by tremie (as specified below) where required.
Water addition for augering and boring holes shall not be permitted unless approved by the Engineer.
c) Bulbous bases
Where required, bulbous (enlarged) bases shall be formed after driven casing has reached required depth. Bases shall be formed by progressively
displacing surrounding subsoil with approved concrete placed by repeated action of a gravity hammer. Base-size depends on the compressibility
of surrounding subsoil but shall in no case have a diameter less than 1,5 times the pile diameter.
d) Inspecting preformed holes
Equipment for inspecting pile shafts shall be provided and operated in accordance with the latest amendment or edition of “Code of Practice
Relating to the Safety of Men Working in Small Diameter Vertical and Near Vertical Shafts for Civil Engineering Purposes”, obtainable from the
South African Institution of Civil Engineers.
Immediately before any reinforcement is installed or concrete placed, the Engineer shall be informed thereof with a view to inspecting pile holes
if deemed necessary. Any potential for collapse of sides must be evaluated by a competent person and the hole only entered if the hole is
adjudicated to be stable and the risk is very small. Where there is any doubt in this regard the hole shall not be entered.
e) Installation Requirements
(i) Underslurry piles
Auger rigs shall be checked for verticality once set up at a pile position. Starter casing shall be installed to protect the top of the pile
from collapse during drilling and shall extend 1,5 m above the ground level. These casings shall be kept full with bentonite slurry at
all times. Pile shafts shall be concreted using tremie techniques. Measurements of the concrete surface and tremie-tip level shall be
taken regularly to check that the tremie is immersed more than 300 mm in concrete at all times. Concrete cover spacer blocks shall
be as specified in the Contract Documentation and shall be sufficiently wide to ensure adequate cover in soft side-wall conditions.
Jaws or grabs used for excavation of barrettes shall be selected by the Contractor considering the materials to be excavated and
width requirements.
All auger underslurry piles and barrettes shall be concreted on the same day that the excavation is completed.
(ii) Displacement auger piles
The piling rig mast shall be adjusted for verticality or rake at the piling position. The flight is rotated and simultaneously advanced to
penetrate with all relevant parameters recorded during penetration. Installation energy shall be calibrated against trial pile test data
to ensure satisfactory pile load capacity. When the required installation energy and penetration depth is achieved, grout/concrete is
pumped through the hollow-stem, and the flight withdrawn during the pumping process. The rate of the flight withdrawal shall be
carefully monitored against the volume of grout/concrete pumped to ensure satisfactory pile shaft integrity. The flight shall be rotated
during concreting/grouting and the flight extraction process to ensure that the full length of penetrated pile shaft is concreted/grouted.
Spoil brought to the surface shall be continuously removed. The head of the pile shall be cleaned before inserting reinforcement
cages into the fluid concrete/grout using vertical crowd or vibrators attached to the cage. Established refusal criteria shall be used to
set pile tip levels for drilled displacement piles.
(iii) Screwed in cased auger piles (SICAP)
The piling rig mast shall be adjusted for verticality or rake at piling positions. The auger and casing are advanced simultaneously to
the design depth with the auger loosening internal soil and conveying it to the surface by auger flights inside casing. The excavated
soil shall be discharged through openings located at the casing-top, underneath the rotary drives. Once the design depth is reached
the flap at hollow-stem-auger base shall be opened and concrete or grout injected to the base of the hollow stem auger. The auger
and casing are simultaneously withdrawn to form the pile shaft. The rate of the flight withdrawal shall be carefully monitored against
the volume of grout/concrete pumped to ensure satisfactory pile shaft integrity. The head of the pile shall be cleaned before inserting
reinforcement cages into the fluid concrete/grout using vertical crowd or vibrators attached to the cage.
(iv) Oscillator piles
The oscillator machine is set up at the pile position and the initial casing, fitted with a cutting edge, is inserted into the oscillator and
clamped. Oscillating the casing backwards and forwards and releasing and raising vertical rams, enables tube-penetration of the soil
under its own weight. Excavation of spoil from the bore of tube using a grab proceeds concurrently with casing penetration. Casings
are coupled via mechanical joints. Boring continues with additional casings added as and when required. Penetration of boulder
layers is achieved with large chisels in combination with cutting edge of pile casing. To reduce jamming risk, casings shall be moved
to lubricate the outside and reduce friction.
Pile holes where chisels are stuck or jammed and cannot be removed, shall be abandoned, the casings filled with sand or other
material as directed by the Engineer and withdrawn. The Engineer shall determine whether a replacement pile is required and shall
instruct the Contractor accordingly. No standing time will be paid in this regard nor will claims for extension of time be considered.
Once bedrock is reached, this shall be penetrated to form a seal against possible ingress of running sand and/or water. Rock sockets
shall be formed by chiselling and cluster drilling to the prescribed depth detailed in the Contract Documentation. Debris shall be
removed before concreting with a suction baler or other appropriate equipment. Reinforcing cages, fitted with roller-type spacers shall

be carefully lowered into position. If permanent liners are specified, these may be attached to the reinforcing cages and lowered as a
unit.
(v) Continuous Flight Auger Piles (CFA)
CFA piling shall not commence until sufficient supply of grout/concrete is present on site to complete a pile. Drilling parameters (auger
rotation speed, penetration rates, crowd, torque, etc.) for the production piles shall be within ranges established in the pile trials. The
auger-advance rate and rotation (established in test pile programme), shall be continuous to prevent excess spoil being transported
to the ground surface with automated monitoring equipment used to verify that target rates of penetration are maintained during
production piling. Penetration rates should generally be maintained such that the auger advance is equal to or greater than the auger
pitch for every 1.5 to 2 revolutions for cohesionless soils, or 2 to 3 revolutions for cohesive soils. Loose cohesionless-soils are more
susceptible to mining by auger flights and require greater attention. In general, refusal is defined as an auger penetration rate of less
than 0,3 m/minute with appropriate project appropriate equipment. Augers shall not be extracted at any time during pile construction
that results in an open unsupported borehole or inflow of water.
Placement of grout/concrete shall commence within 5 minutes of auger achieving planned depth. Placement of grout/concrete shall
be continuous and monitored using automated systems to ensure adequate volumes are always pumped at positive pressures as
auger-withdrawal is in progress. Augers shall not be allowed to turn in place without either drilling or pumping taking place. Where
stoppages occur, holes shall be re-drilled.
Appropriate volumes of grout/concrete shall be delivered to the pile when the auger is near to the surface and significant positive
pressure cannot be maintained. Completion of the pile-top requires manual work to remove debris, soil or contaminated grout/concrete
before reinforcement is placed into the fluid grout/concrete. The Contractor shall use a small form at the pile top, extending above
level, to maintain a sound pile surface.
Reinforcing steel shall be lowered into the grout/concrete by gravity or pushed gently to final position by hand, vibrated, or mechanical
means while it is in a fluid state before set. It shall be held in position near the ground surface within the fluid grout/concrete column
by supports, appropriate for the reinforcement used, which shall remain in place until it reaches initial set, or 24 hours, whichever is
longer.
Pile termination/refusal criteria, if applicable, shall be established during trial pile installation. If refusal is encountered before the
planned depth is achieved, the rotation of auger shall be stopped, and the Contractor shall inform the Engineer. Installation data shall
be evaluated and determined whether the established termination-criteria were met, or if other action is required for pile completion.
Adjacent piles within six diameters, centre to centre, of each other shall not be installed until it is demonstrated by the pile Contractor
that the grout/ concrete in the first pile installed, is fully set. Grout/concrete set shall be such that the integrity of existing piles will not
be compromised if drilling new piles causes mining of soil away from existing piles.
(vi) Driven cast in situ piles
A plug of dry gravel or sand shall be formed at the pile-tube-base by light tapping with the hammer. Hammer drop is increased to
drive the tube into the ground by successive blows as the plug arches in the tube simultaneously preventing ingress of water and/or
soil. The number of blows for 250 mm tube-penetration is monitored to generate a record of drive resistance especially and when
near the expected full depth. Tubes are driven to the depths specified in the Contract Documentation or to such depth as indicated
by the Engineer after trial pile installation. On reaching full depth, the plugs are driven out of the tube-end by successive blows of the
hammer. The tubes are held in place by extraction winches as the base plug is expelled. Thereafter, enlarged bases are formed by
gradually feeding zero-slump concrete into the tubes while at the same time continuing with measured hammer blows expelling
concrete to form the base. The volume of concrete expelled and the number of blows is continually recorded and compared with the
theoretically calculated energy required for the required load capacity until the size of the enlarged base meets the specification. On
completion of the enlarged bases, the steel shaft reinforcement is inserted.
Shafts may either be formed with a zero or a high slump concrete. Zero slump concrete is used in conjunction with hammer blows
when an irregular shaft is required but care must be exercised to prevent damage to the main and especially spiral reinforcement.
High slump concrete is generally used. For both concrete types, tubes are extracted as the concrete is placed. Care shall be taken
not to extract the casings too rapidly and, cages shall be continually checked for possible uplift to negate voided-concrete and other
problems.
f) Rock sockets
Where required, rock sockets, to the required dimensions, shall be formed in rock formations of adequate strength, quality and thickness, for
transmitting specified loads. No separate payment will be made for socketing into rock other than under pay item C12.1.6.3.
g) Reinforcement
Reinforcing steel shall be free of oil, soil, excessive rust or other deleterious material. Reinforcement shall not be placed in pile holes until
immediately before concreting. It shall be accurately maintained in position without damaging pile sides or the reinforcing itself. Approved circular
cementitious or other approved spacers shall be placed at approved intervals and positions to maintain the reinforcing steel at required distance
from inside face of pile casing or pile hole wall. Spacers shall be manufactured out of concrete of the same quality as pile so as not to cause
zones through which aggressive ground water may penetrate.
Pile reinforcement is not be shown in the bending schedules. Only the number, diameter and type of bars and their arrangement will be shown on
the drawings. The Contractor may replace bars shown on the drawings with bars of different diameter, spacing and type, of equivalent strength if
Reinforcement shall be assembled in cages, sufficiently robust to prevent permanent deformation during handling. For cast-in-situ piles, the insides
of cages shall be kept open ensuring unrestricted placing of concrete.
Spiral reinforcement shall be tied to longitudinal bars at a spacing of less than 300 mm unless otherwise shown on the plans.
Longitudinal bars shall project above cut-off level as shown on the drawings, or by 40 times the bar diameter if no dimensions are shown.
Splicing reinforcing may be instructed to increase cage-length and the Contractor shall keep available sufficient steel reinforcing on site to enable
the assembly of additional lengths of pile reinforcing whenever necessary.

h) Provision for pile integrity testing
The Contractor shall provide and install 50/85 mm diameter mild steel tubes of 3,0 mm wall thickness for “Cross Hole Sonic Logging” in all test
piles and designated piles as per Clauses A12.1.8.4 and A20.1.5.6c) of Chapter 20. Frequency response (pile tapping) is compulsory for all piles
cast.
i) Casing
Generally temporary or permanent casing shall be installed full depth to prevent ingress of material from the sides of hole into the concrete. With
the Engineer’s approval, but at his own risk, the Contractor may halt casing installation in self-supporting materials except at hole-top where
concrete is placed under drilling mud. Casing should not extend into sockets. Casing shall be installed by approved means when required by the
pile type and/or as dictated by subsoil conditions including sidewall collapse and water ingress. Individual lengths shall be adequately joined.
Jamming of casing or loss of casing shall be immediately brought to the Engineer’s attention Voids formed outside permanent casing shall be
filled with approved material.
j) Concreting of piles
Concreting or grouting of piles shall not commence until approved by the Engineer. The Contractor shall be responsible for design of the concrete
mix/grout mix used to form piles. It shall be so proportioned as to be of sufficient strength and workability to enable proper placement, and, where
self-compacting concrete is not used, it shall be thoroughly compacted by approved means. Extraction of temporary casings during placement of
concrete shall be such that no damage is caused to the pile and the advancing concrete level is at all times kept considerably above the temporary
casing's trailing edge.
If pile excavations are dry, the concrete is deposited into the pile via a chute which prevents it from striking the reinforcing cage as it descends to
pile toe. Concrete with a slump greater than 175 mm should be used and the mix designed to be self-compacting. The pile head shall be vibrated
to ensure compaction.
The requirements of Clause A13.4.11c) of Chapter 13 together with the following requirements shall apply when concrete is placed under water
by tremie:
- Cement content shall be greater than 350 kg per m3 and slump shall be greater than 175 mm,
- The hopper and tremie shall be a closed unit which cannot be penetrated by water,
- The tremie shall be greater than 150 mm in diameter for 20 mm aggregate and wider for larger aggregates,
- Concrete shall be so placed as to prevent mixing of water and concrete,
- The tremie shall at all times penetrate concrete,
- Placing concrete below water level in the casing shall be done in one operation, and the same method of placing concrete shall be maintained
throughout,
- Before placing the concrete in water, the Contractor shall ensure that no silt or other materials have collected at the pile base. Where drilling
mud is used, the Contractor shall ensure that no drilling mud suspension with a relative density greater than 1.3 has collected at the pile
base,
- Tremies shall be thoroughly cleaned before and after use,
- Whenever practicable, concrete shall be placed in a manner that prevents segregation.
A12.1.7.8 Precast piles

a) Precast concrete piles
(i) General
Piles shall be of reinforced or prestressed concrete and shall be manufactured, handled, stored and installed in accordance with BS
8004, unless otherwise specified in the Contract Documentation.
The Contractor shall confirm the design of piles to ensure their ability to accommodate external loads and applied bending moments
incurred during handling, transportation storing and installation. All pile designs shall comply with the requirements of BS 8004 and
TMH 7, Part 3 as applicable, and shall contain at least the minimum steel as shown on drawings. The Contractor shall, prior to the
planned installation of precast piles, provide the Engineer with test data indicating the strength/age development of the concrete used
in the manufacture of each pile/ pile batch as specified in the Contract Documentation to ensure that the piles have attained sufficient
strength before driving. Piles damaged in transit or negligent handling shall be rejected and not be paid for.
The Contractor shall via a method statement submit details of the design confirmation and pile driving criteria to the Engineer for
approval at least 3 weeks before commencing with pile installation.
(ii) Manufacture
The piles may be manufactured in a factory or casting yard on the site. The Contractor shall ensure that the factory or casting yard,
plant and equipment, materials and products shall at all reasonable times be accessible for inspection by the Engineer. The Engineer
shall be informed of imminent casting of each pile/batch of piles and shall be assisted as necessary in the sampling and testing of
concrete. Such testing shall not relieve the Contractor of his obligations in terms of the contract. Piles shall be cast on a rigid horizontal
platform in approved moulds. Moulds shall be fitted with devices for locating and aligning mechanical joints or coupler sockets and
pile shoes. These shall be accurately aligned so that when sections are coupled together on site, the shaft of combined piles is
straight. The upper surface of pile concrete shall be smoothed with a steel trowel such that no irregularities cause pile deviation while
driving. Adequate provision shall be made for the safe lifting of piles. Each pile shall be clearly marked with the date of casting,
reference number, and with distance marks from pile-tip at 1,0 m intervals. Piles shall be cured for a period sufficient to develop the
strength required to withstand, without damage to the pile, stresses caused by handling, transporting, storing and driving. Such
parameters shall be clearly indicated in the method statements for the manufacture of piles. Piles shall not be driven before the pile-
concrete has attained the specified strength.

(iii) Handling, transport and storage
Care shall be taken at all stages of lifting, handling and transporting to ensure that the piles are not damaged or cracked. Piles shall
be stored on firm ground that will not settle differentially under the mass of pile stacks. Piles shall be placed on timber supports which
are true in level and spaced to avoid undue bending in piles. Supports in the stack shall be located vertically above one another.
(iv) Precast test piles
Test piles shall be installed at positions shown on plans at the locations and to the penetration depths required.
All test piles shall be driven with impact hammers unless specifically stated otherwise in plans. Driving equipment used for test piles
shall be identical to that which the Contractor proposes to use in production piling. Test piles shall be driven to a driving resistance
established by the Engineer at the estimated pile toe elevation. Test piles which do not attain the driving resistance specified at a
depth of 250 mm above the estimated pile toe elevation shown on the plans shall be allowed to "set up" for 12 to 24 hours, or as
directed by the Engineer, before being re-driven by applying at least 20 blows to the pile. If the specified driving resistance is not
attained on re-driving after 12-24 hours, the Engineer may instruct the Contractor to drive a portion or all the remaining test pile length
and repeat the "set up" re-drive procedure. Test piles driven to the indicated position and not having the driving resistance required,
shall be spliced and driven until the required capacity is obtained. A record of driving of the test pile shall be prepared by the
Contractor, including number of hammer blows per 250 mm for the entire driven length, as-driven length of the test pile, cut-off
elevation, penetration in ground, and any other pertinent information. The Contractor shall provide all relevant information in records
to the Engineer. If a re-drive is necessary, the Engineer will record the number of hammer blows per 25 mm of pile movement for the
first 250 mm of re-drive. The Contractor shall not order piling to be used in permanent structures until the test pile data is reviewed
and pile order lengths are approved by the Engineer. The Engineer will provide pile order lists within 7 calendar days after completion
of all test pile driving specified.
(v) Lengthening of precast piles
Full length piles shall always be used where practical and possible. Where splices are unavoidable for steel or concrete piles, these
shall comply with the details given in the Contract Documentation. The number, locations and details shall be subject to the approval
of the Engineer. Mechanical splices for concrete or steel piles may be approved by the Engineer if the splice can transfer the full pile
strength in compression, tension and bending. Splices for cast in place piles, shall be watertight.
Care shall be taken to ensure that additional lengths of pile joined are truly axially in line with the original pile within tolerance
requirements for straightness set out in Clause A12.1.8.1a).
Driving shall not be resumed until the pile extension and any bonding agent used has attained required strength.
b) Steel tube piles
Where specified, or if offered as an alternative by the Contractor and accepted by the Engineer, hollow steel piles, either filled with concrete or
not, may be constructed. If adequate connections are provided between steel and concrete to transfer loads, the concrete may be deemed to
assist in carrying load.
Tubes can be either top or bottom driven. Bottom driven is generally more efficient as a large proportion of hammer energy is absorbed by the
tube itself increasing risk of casing fracture for top driven. The lead section of tube is lifted and positioned in the leader which shall be adjusted
for verticality or rake. Drop hammers which operate within pile-bore, act on a plug of dry concrete, about 3 to 4 diameters in length. The plug is
continually refreshed by adding additional material to prevent splitting of the tube. When the required set is achieved, driving is complete and the
hammer is removed from the tube.
Casings shall be manufactured to high standards of quality control and appropriate casing thicknesses shall be used to prevent splitting or end
distortion.
For corrosion protection, steel piles shall be coated in bitumen or synthetic resins to the satisfaction of the Engineer or as specified in the Contract
Documentation. Cross-sectional area of wall steel shall be adapted to aggressiveness of subsurface conditions, to compensate for possible
reduction in pile wall thickness caused by abrasion and corrosion during the service life of pile.
c) Steel section piles
H-pile sections are lifted by the piling rig and located into the piling helmet which is then released from the hammer. The first shaft section together
with a helmet is lowered onto the pile position and the hammer positioned to rest on the helmet. The leader of the piling rig shall be adjusted for
verticality or rake.
Piles may be driven with vibratory, drop, or hydraulic hammers. Once the first shaft section is driven the second prepared-for-welding section, is
lifted up and lowered to line up with the first section. Guiding lugs, tack-welded to the first section shall be employed to facilitate this operation.
Sections shall then be butt-welded together. Where practical, full length piles shall be used. Where splices are unavoidable, their number, locations
and details shall be subject to approval of the Engineer. Splices in steel piles and pile casings shall be welded in conformance with the relevant
welding code.
Driving is continued and the cycle repeated for further lengths. The pile is driven to the set calculated to provide adequate bearing capacity. The
set should be checked after 24 hours to determine if there is any relaxation.
Should relaxation be evident, piles should be re-driven until the required set is achieved and again checked after 24 hours. When the required
set is achieved, heads of piles shall be trimmed to the correct level.
d) Ductile Iron Piles (DIPs)
Based on site specific soil conditions, piles can be installed as end-bearing (non-externally grouted) or friction (externally grouted) piles.
These piles are started by laying the grout shoe and inserting the spigot end of the pile shaft into the conical point. The pile shall be kept in place
by a series of keeper plates within the conical grout shoe. On driving, the conical grout shoe creates an annulus between pile shaft and surrounding
soils. This annulus shall be immediately and consistently filled with a sand grout pumped down the pile shaft and exits within spaces between the
keeper fins in the conical points. The breaker hammer driving tool shall be fitted with a special grout box adapter to allow grout to flow from the
grout pump through the driving tool into the upper most pile shaft.
Piles are driven to refusal or to the required penetration depth with the use of a tracked high-impact high-frequency hydraulic hammer (ie. breaker
hammer). On drive-completion, the pile is cut off to the required level. The remaining pile section may be fitted with the appropriate driving shoe
to serve as the lead section for the next pile. All cut-off sections may be re-used employing suitable couplers. Completed piles are fitted with an
appropriate pile cap plate.

Externally grouted or friction piles are installed using an oversized conical grout shoe attached to the base of lead pile section. As the pile is
driven, the annulus created between pile shaft and the soil is filled simultaneously with a sanded grout, bonding the pile shaft to surrounding soil.
An appropriately-sized bearing plate shall be seated onto the pile with a reinforcing bar or other indicated termination mechanism
e) Self-drilling micropiles
The piles are formed from a fully threaded steel bar with a hollow core which is drilled and simultaneously grouted into soils without a casing using
a sacrificial bit mounted on the first section of load bearing elements. Additional pile length is obtained by attaching additional element using
couplers. The micropiles are installed employing rotary percussive techniques.
Grout is injected through the hollow bar with a continuous flush returned to the surface ensuring permanent support is maintained to the
surrounding ground. Self-drilling micropiles are installed using small piling rigs and are particularly suited to axial compression and tension loads
and can easily be installed at raking angles. A variety of sacrificial drill bits are available to suit different ground conditions. Temporary casing is
not required and is thus suited to use in collapsing and problem ground. Applications include bearing and tension piles as well as soil nailing and
ground anchorages.
The loadbearing elements and the coupling nut are to be tightened against one another with a torque M as provided by the manufacturer of the
self-drilling anchor (SDA) to ensure a sufficient locking effect. Care must be taken to not exceed the maximum values for torque, blow impulse
and blow energy as per SDA’s manufacturers details.
The torque may be applied by using a calibrated torque wrench or the rotation mechanism of the hammer drill with the assistance of the hydraulic
clamping mechanism of the drill rig.
During drilling, a cement/water suspension is to be used as a flushing fluid and initial stabilisation of the borehole. The drilling rate shall not exceed
1,0 m per minute with approximately 50 rpm. using a flushing pressure of 10-15 bar.
On reaching the intended depth of the pile, injection must be carried out with a cement grout compliant with SANS 50206.
The grout volume injected must be large enough to ensure that the flushing suspension is completely displaced and ejected from the borehole.
To avoid voids in the grout body, the reservoir containing the cement grout may not be pumped empty during the injection procedure.
The installation and construction of self-drilling micropiles shall be monitored and recorded in compliance with SANS 54199 using the guideline
for a micropile installation log as per Annex D.
f) Driving piles
(i) General
(ii) At least 3 weeks before driving any piles, the Contractor shall submit method statements based on the information furnished on the
drawings detailing the methods he proposes to use to drive each pile to its full depth in one continuous operation (with due allowance
for coupling time). Pile-installation frames
Piles and pile casings shall be driven with a gravity hammer, a rapid-action power hammer or by other approved means. Prestressed-
concrete piles shall be driven with a hammer of mass of at least equal to that of the pile. Other pile types shall preferably be driven by
a hammer with similar mass characteristics. The hammer shall not, during driving operations, damage any permanent components of
the pile. Pile driving leaders shall be constructed in such a manner as to afford freedom of movement of the hammer and shall be
held in position to ensure adequate support for the pile or pile casing during installation. Inclined leaders shall be used for installing
raking piles.
The heads of all piles shall be plane and perpendicular to the longitudinal axis of the pile before the helmet is attached.
Heads of precast concrete piles shall be protected with a pile cushion constructed from resilient material, care being taken to ensure
that it is evenly spread and held in place. A helmet shall be placed over the packing, and a dolly of hardwood or other material not
thicker than the diameter of the pile shall be placed on top. During pile driving, pile cushions shall be changed as described above
before excessive compression or damage takes place. Approval of pile driving equipment shall not relieve the Contractor of the
responsibility for piles damaged caused by misalignment of the leads, failure of cushion materials, failure of splices, malfunctioning of
the pile hammer, or other improper construction methods. Piles damaged for such reasons shall be rejected and replaced at the
Contractor's expense.
Standing time shall only be paid for pile-installation frames standing during normal working hours as laid down in the general conditions
of contract for such periods during which the pile-installation work has come to a standstill following an action by the Employer.
As soon as the pile-installation frames have come to a standstill, the Contractor shall inform the Engineer, in writing, that he intends
to claim standing time, and shall also furnish full particulars of the action which gave rise to the claim and a list of pile-installation
frames in respect of which standing time will be claimed, complete with date and time.
The period in respect of which a claim is lodged shall become operative from the moment when the notice has been handed over to
the Engineer and shall continue until the restriction has been removed and normal procedure may be resumed.
(iii) Ultimate pile capacity
Piles shall be driven by the Contractor to the penetration depths shown on the plans or to a greater depth if necessary, to obtain the
ultimate capacity. Ultimate pile capacity shall be specified by the Engineer.
The ultimate pile capacity of jetted piles shall be based on the driving resistances recorded during impact driving after the jet pipes
are removed. Jetted piles not attaining ultimate pile capacity at ordered lengths shall be spliced and driven with an impact hammer
until the ultimate pile capacity is achieved. Splicing shall be to the Contractor’s cost. The ultimate pile capacity of piles driven with
followers shall only be considered acceptable when follower-driven piles attain the same pile toe elevation as full length piles driven
without followers, which attained the required ultimate pile capacity.
Ultimate pile capacity of piles driven with vibratory hammers shall be based on driving resistances recorded during impact driving after
the vibratory equipment is removed from the first pile in each group of 10 piles. Vibrated piles not attaining the ultimate pile capacity
at the ordered length shall be spliced, as required, at the Contractor's cost, and driven with an impact hammer until ultimate pile
capacity is achieved.

(iv) Preboring/Water jetting
Augering, wet-rotary drilling, water jetting or other methods of pre-boring shall be used only when approved by the Engineer. When
permitted, such procedures shall be carried out in a manner which will not impair the capacity of piles already in place or the safety
of existing adjacent structures. Except for end-bearing piles, pre-boring shall be discontinued before the leading end of the pile
reaches a depth of 80% of anticipated final depth or a depth as agreed with the Engineer and the pile driven with an impact hammer
to a driving resistance specified by the Engineer. Where piles are to be end-bearing on rock or hardpan, pre-boring may be carried
to rock-surface or hardpan, and the piles re-struck with an impact hammer to ensure proper seating. If the Engineer determines that
pre-boring disturbed the capacities of previously installed piles, those piles disturbed shall be restored to conditions meeting
requirements of this specification by re-driving or by other methods acceptable to the Engineer. Re-driving or other remedial measures
shall be instituted after pre-boring operations in the area are complete. The Contractor shall be responsible for costs of any necessary
remedial measures, unless pre-boring methods were specified in the Contract Documentation and properly executed by the
Contractor.
In the case of soldier piles the Engineer may approve augering of holes prior to steel insertion to facilitate attaining of the position and
verticality tolerances. Where so indicated or instructed the annulus shall be filled with concrete or grout between the H-Pile section
and the soil. Below excavation level this may be strength concrete as specified in Contract Documentation or nominal strength
concrete or grout above excavation level.
(v) Installation sequence
Unless otherwise specified or ordered, pile installation sequence, shall be left to the Contractor. However, the sequence for driving
piles in a group shall be programmed to minimize the creation of consolidated blocks of ground into which piles cannot be driven or
which cause fictitious penetration values. Piling shall generally commence at the group-centre and progressively extended to the
perimeter unless otherwise approved by the Engineer.
Installation of piles shall be undertaken in such a manner that structural damage, distortion or positioning defects to previously installed
piles or casings does not occur.
Partially driven piles shall not be permitted to stand overnight due to dissipation of pore water pressure.
(vi) Practical and absolute refusal
Practical refusal is defined as 20 blows per 25 mm of penetration with hammers operated at the maximum fuel or energy setting, or
at a reduced fuel or energy settings determined by the Engineer based on pile installation stress control. In no case shall driving
continue for more than 75 mm at practical refusal driving conditions. Absolute refusal is defined as a penetration resistance of more
than 50 % of the practical refusal, i.e. 30 blows per 25 mm. Driving shall be terminated immediately once absolute refusal driving
conditions are encountered.
g) Pile heave
In some soils, such as saturated cohesive soils, installation of the piles may cause previously installed piles to heave. The Contractor shall place
accurate level marks on each pile immediately after installation and shall take level readings immediately after the pile is driven and again after
piles within a radius of 5,0 m were driven to determine pile heave range. All piles that have heaved more than 6,0 mm shall be re-driven to the
required resistance, unless re-driving tests on neighbouring piles show this to be unnecessary. Piles shall not be concreted neither shall any pile-
capping slab be constructed until the piles within the defined heave-influence zone (5,0 m) are re-driven as required.
If pile heave is detected for pipe or shell piles filled with concrete, piles shall only be re-driven to the original position after the concrete has obtained
sufficient strength and a proper hammer-pile cushion system, acceptable to the Engineer, is used.
All work performed in conjunction with re-driving piles due to pile heave shall be measured for payment provided the initial driving was done in
accordance with approved or specified installation parameters and sequence.
h) Pile alignment
Tolerances given in Clause A12.1.8 shall be the maximum permissible deviations from specified dimensions, levels, alignment, positions, etc,
shown on the drawings of the structures or structural members.
Where inclination of a precast concrete pile deviates from the correct slope during installation, the pile shall not be forced into the correct position.
The slope of guiding frame shall be adjusted so as to coincide with actual pile inclination to preclude bending of the pile. Where verticality or
inclination of installed piles falls outside specified tolerances, the pile will be classified as defective and be replaced at the Contractor’s cost.
i) Determining pile length
The design of the piles and pile groups, and the quantities in schedule of quantities, are based on subsurface data shown on the drawings. The
Engineer will determine the depth of piles for measurement as work proceeds.
Where variations in subsurface conditions occur in respect of material and depth of the water table, the Engineer shall be informed immediately.
If the Contractor is not satisfied that the piles will be capable of carrying the specified loads at the depths determined by the Engineer, he shall, in
consultation with the Engineer, lengthen the piles to reach a suitable founding depth. Where Engineer and Contractor cannot agree on the founding
depth, the Engineer may require the Contractor to -
- Undertake additional foundation investigations and/or core drilling in accordance with sub Clauses A12.1.3.3 and A12.1.8.3 respectively,
and/or
- Install one or more test piles and conduct load tests in accordance with Clause A12.1.8.4 and integrity testing in accordance with Clause
A12.1.8.4c). The Engineer will prescribe the positions for each test pile. Test piles shall comply with the specified requirements.
It is required that the top section of each pile has a minimum length of 2,5 m below the pile cap before the coupler or such greater length as
directed by the Engineer. The Contractor shall submit the minimum length he proposes to use to the Engineer for approval.
j) Stripping pile heads
Precast piles shall be installed to a level of at least 1,0 m above the minimum length required and cast in situ piles to at least 150 mm above the
minimum length required. Excess concrete shall be stripped, so that only sound concrete projects into the pile-cap.
Before a pile head is stripped, a cut-off plane shall be marked by cutting a 20 mm deep groove with a grinding-machine along the full circumference
of the pile. Heavy concrete demolishing equipment may not be used for pile head stripping. All loose material shall be removed from the minimum
length required.

Concrete shall be stripped so that the pile below cut-off level will not be damaged, or, should defective concrete be found in completed piles,
damaged or defective concrete shall be cut away by Contractor at his own cost and replaced with new concrete well-bonded to old concrete, or
the pile shall be replaced as directed by the Engineer.
The main reinforcement of piles, shall extend more than 40 times the diameter of the reinforcing bar, beyond the cut-off level into the pile-cap.
This reinforcement shall be left straight unless otherwise directed by the Engineer. Cut-off levels for piles shall be as shown on the drawings.
k) Piling data
The following data on each pile installed shall be recorded in a form prescribed by the Engineer:
- Effort used for driving pile and resistance to penetration at founding level.
- Description of subsurface material penetrated, presence of ground water and quality of material at pile tip founding,
- Quality of materials used in construction or manufacture of piles,
- Quality of permanent casing used,
- Method of placing and compacting as well as volume of concrete in cast in situ piles,
- Method of founding of piles e.g. bulbous bases, rock sockets, etc, and their dimensions
- Working load of pile,
- Length of pile and accuracy of installation in respect of position and inclination,
- Nominal dimensions and type of pile,
- Length and details of any temporary and permanent casings used,
- Position of pile.
A12.1.8 WORKMANSHIP
Unless otherwise specified in Contract Documentation the tolerances given below shall be the maximum permissable deviations from the specified
dimensions, levels, alignment, positions, etc, shown on the drawings of the structures or structural members.
a) Piles:
Position ………………………………………………. 0,167 times the diameter of the pile, or 100 mm, whichever shall be the greater
External dimensions:
Prefabricated piles …………………………………………………………………………….……………………………….. 25 mm ± 5,0 mm
Cast in situ piles …………………………………………………………….………….. plus-tolerance not specified, minus-tolerance 0 mm
Pile head level: Average level
of trimmed /cut pile head …………………………………………………………………………………………….…………………. ± 25 mm
Verticality or rake …………………………………………………………………………………………………….………………………. 1,5 %
Straightness:
For precast piles the maximum deviation from straight is 5,0 mm for piles up to 3,0 m in length and 1,0 mm more for each additional metre of pile
length.
b) Self-drilling micropiles:
(i) Construction tolerances as per SANS 54199 shall be permitted unless otherwise specified in Contract Documentation.
(ii) Those geometrical deviations include the following as per SANS 54199 Section 8.2 and figure 5:
(iii) Plan location of vertical and inclined micropiles measured at working level: ≤ 0.10 m
(iv) The horizontal deflection at the top of the projected micropile cap under ultimate loading shall be limited to 5,0 mm
(v) Deviation from the theoretical axis:
1. Vertical micropiles: max 2 % of the length
2. Inclined micropiles: n ≥ 4, max 4 % of the length
3. Inclined micropiles: n < 4, max 6 % of the length
Any pile outside of these tolerances shall be subject to review by the Engineer and may be rejected or replaced at the Contractor’s expense. Any
re-design necessitated by non- compliance shall be carried out by the Engineer at the Contractor’s cost.
A12.1.8.2 Concrete and grout

All concrete for structural work associated with piling and which is not covered elsewhere in the project document shall comply with the provisions
of relevant Clauses in Section A13.4 of Chapter 13. If specified in the Contract Documentation all concrete used for piles shall Prescribed
Composition (Class P) concrete or Durable (Class D) concrete as described in Clauses A13.4.7.8 and A13.4.7.7 of Chapter 13 respectively.
The characteristic cylinder strength shall be determined using 150 mm diameter, 300 mm high cylinder or the characteristic cube compressive
strength shall be determined using 150 mm cubes and all test specimens shall be prepared strictly in accordance with SANS 3001-CO2-2 and

tested in accordance with SANS 3001-CO2-3 at both 7 and at 28 days. All concrete shall be categorized in the compressive strength classes as
shown in Table A13.4.7-15 of Chapter 13.
Class D concrete shall be assessed from cores obtained from test panels constructed in accordance with test panels in accordance with Clause
A13.4.7.10e) of Chapter 13. Durability concrete and steel cover shall be assessed according to A20.1.7.5c) (Judgement Plan A) of Chapter 20.
Refer to Clauses A13.4.8.1, A13.4.8.2 or A13.4.8.3 of Chapter 13 for tolerances, compliance and non-compliance with the specified requirements.
The consistency of each concrete batch mixed shall be tested with the slump test according to SANS 5862-1:2006 or SANS 5862-2:2006,
whichever is applicable. Self compacting concrete shall be tested in accordance with SANS 3001-C01-9.
The fluidity and of each grout batch mixed shall also be measured with a flow cone in accordance with Clause A 13.5.5.9 of Chapter 13 and, if
specified, with a viscometer. For stiffer grouts and grouts with fine aggregate as for CFA piling applications a modified CRD flow cone with an
enlarged (up to 19 mm diameter) orifice complying with ASTM1939 is used. Any variation exceeding 20 % of the average daily recorded values
shall be immediately brought to the attention of the Engineer.
The results of tests on concrete shall be assessed according to Clause A20.1.7.5d) (Judgement Plan B) of Chapter 20. Strength tests on grout
will be assessed for acceptance if the average strength exceeds the specified strength with no single test result having a strength of less than
95% of the specified strength.
A12.1.8.3 Core drilling

The Engineer may instruct rotary core drilling to be done with a view to obtaining cores of the founding formation and/or of the concrete in the
completed structural member. In the case of piling, the core drilling may precede the piling or may be done through the completed pile, as specified,
or as instructed by the Engineer.
The Contractor shall supply the necessary construction plant on the site for drilling under the above conditions. The plant and techniques used
shall be suitable for ensuring maximum core recovery. The diameters, depths and diameters of the cores shall be as specified in the Contract
Documentation.
All drilling shall be in compliance with the Standard Specifications for Subsurface Investigations issued by SANRAL.
The Contractor shall keep accurate records of the drilling, which, together with the cores, shall be handed over to the Engineer. The cores shall
be sheathed and placed in the correct sequence in approved core boxes marked as prescribed. The core boxes shall be stored under cover.
Where provided for in the Contract Documentation and/or as instructed by the by the Engineer the Contactor shall arrange for the testing of
selected borehole core samples. Testing of cores for compressive strength shall be done in accordance with SANS 3001-C03-5
A12.1.8.4 Load tests on piles

The Engineer may order load testing on certain selected piles and/or test piles. The procedure for loading tests shall comply with the
requirements of Clause A20.1.5.6c) of Chapter 20.
a) Static load test
(i) General
During the period of testing, driving of other piles which may affect the testing shall cease. For driven precast piles, the Contractor
shall make each designated concrete and/or steel pile available for taking of wave speed measurements prior to placement in the
leads
Working piles may be used as anchor piles if approved and provided they are suitably reinforced and are designed for tension. Where
anchor piles or earth anchors are required for providing reaction, they shall be so placed as to have a minimal effect on the test results.
The Contractor shall provide the complete testing assembly, the necessary plant, equipment, instruments and labour for carrying out
the test and for determining accurately the settlement of the piles under each increase or decrease of the load. The test assembly,
plant, equipment and instruments used shall be subject to the approval of the Engineer via a method statement submitted by the
Contractor.
Within two days of having completed the tests, the Contractor shall supply the Engineer with the test results and neatly plotted load
against settlement, load against time, and settlement against time graphs.
(ii) Loading
The maximum test load applied shall be equal to twice the specified working load or the ultimate test load, whichever shall be the
smaller.
The maximum working load shall be half of the maximum test load or the test load which corresponds with the allowable settlement,
whichever shall be the smaller.
The allowable settlement shall be as specified on the drawings or in Contract Documentation.
(iii) Ultimate test load
The ultimate test load in the compression-load test shall be the load where settlement suddenly increases disproportionately to the
load applied.
The ultimate test load in the tension-load test shall be the load where the upward movement suddenly increases disproportionately to
the load applied or the load producing a permanent rise of 10 mm at the top of the pile, whichever is the smaller.

(iv) Testing self-drilling micropiles
Testing of self-drilling micropiles must be performed according to SANS 54199.
Preliminary (investigation) and working (production) micropiles can be subjected to load testing procedures. Unless otherwise
specified, static load tests on at least 2 micropiles shall be performed for the first 100 micropiles and 1 for every subsequent 100
micropile. Unless otherwise specified for tension micropiles, static load tests shall be performed on at least 2 micropiles for the first
50 micropiles and 1 for each subsequent group of 50 micropiles.
The type, frequency and conditions of the micropile load testing shall be included in the project specifications.
When static load tests are used to control production pile driving, the time required to analyse the load test results and establish driving
criteria shall be specified in the Contract Documentation so that the delay time to the Contractor is clearly identified.
b) Dynamic load testing
Where provided for in the Contract Documentation, Dynamic Load Testing shall be carried out on selected installed piles. Such testing shall only
be carried out by competent independent practitioners. Dynamic measurements following procedures set forth in ASTM D-4945 shall be
conducted.
Should the test/s reveal non-compliance, the Contractor shall re-strike the test pile with the dynamic testing instruments attached after the periods
indicated in Table A20.1.5-2 of Chapter 20, as agreed with the Engineer. A cold hammer shall not be used for the re-strike. The hammer shall be
warmed before re-strike, by applying more than 20 blows to another pile or to timber mats placed on the ground. The maximum amount of
penetration required during re-strike shall be 150 mm, or the maximum total number of hammer blows required will be 50, whichever occurs first.
After re-striking, the Engineer will either provide the cut-off elevation or specify additional pile penetration and testing.
The following re-strike durations shall apply:
Table A12.1.8-1: Re-strike durations
OIL TYPES TIME DELAY UNTIL RE-
STRIKE
Clean Sands 1 day
Silty Sands 2 days
Sandy Silts 3-5 days
Silty Clays 7-14 days*
Shales 10-14 days*
* - Longer times may be instructed by the Engineer.
c) Pile Integrity Testing (PIT)
The purpose of integrity testing is to prove that construction techniques employed to create a pile are satisfactory in terms of quality assurance
with respect to aspects such as necking of concrete in the pile shafts, checking concrete cover to reinforcement, checking for honeycombing or
grout loss, segregation of aggregate inclusion and for large cracks or voids. Where provided for in the Contract Documentation or as instructed
by the Engineer PIT shall be carried out on designated piles and/or on test piles
These tests include:
- Reinforcement cover tests. The Contractor shall have an approved cover meter on site for use by the Engineer during piling installation. No
extra payment will be made therefore and the costs thereof are deemed to be included in the Contractor’s rates for establishment for piling,
- Impulse or Impact Frequency Response (IFR) or “Tapping” method,
- Cross-Hole Sonic Logging (CHSL). For this purpose, either 50 mm (if later drilling through is not foreseen or 85 mm (for drilling through with
an NX core, mild steel access pipes, 3-5 tubes per pile, are to be installed in designated piles as specified in the Contract Documentation,
- Base Integrity Test,
- CAPWAP -Case Analysis of Piles using the Wave Application Protocol.
Base integrity testing comprises the drilling through the pile concrete or where installed, through the steel tubes cast into the piles for CHSL testing,
into the material below the tip of the pile to investigate the integrity thereof. Logging and assessment of the core data shall be done by a qualified
person, who shall be approved by the Engineer. The core logging shall be done in general accordance with the “Guidelines for soil and rock
logging” compiled by the Geotechnology Workshop and published by SAICE in 1990.
Details of the other tests are given in Clauses A20.1.5.6c)(ii) to A20.1.5.6c)(v) of Chapter 20.
Payment shall be made for the carrying out of these tests under pay item C12.1.30.
d) Defective piles
The test pile and the piles represented by the test pile shall be classified as defective if shown in terms of Clause A12.8.4a) or A12.8.4b) to have
a maximum working load of less than the specified working load, or to exhibit excessive settlement. Defective piles shall also include piles damaged
beyond repair, piles with structural defects, or piles which do not comply with the tolerance requirements of Clause A12.1.8.1.
Defective piles shall be corrected by the Contractor at his own cost, by applying one of the following methods approved by the Engineer:
- Extracting the pile and replacing it with a new pile
- Installing a new pile adjacent to the defective pile
- Lengthening the pile to the correct length if defective in length only
- Re- driving heaved piles
- Altering the design, to fit in with the new conditions caused by the defective pile(s).
The method used in driving piles shall not subject the piles to excessive or undue abuse producing crushing and spalling of concrete, injurious
splitting, splintering, and brooming of the wood, or deformation of the steel. Misaligned piles shall not be forced into the proper position. Any pile
damaged during driving by reason of internal defects, or by improper driving, or driven out of its proper location, or driven below the designated
cut-off elevation, shall be corrected by the Contractor, without added compensation, by approved methods.

Piles bent during installation shall be considered defective unless the ultimate capacity is proven by load tests performed at the Contractor's
expense and provided that there are no other negative effects caused by such bending. If tests indicate inadequate capacity, the Engineer shall
determine which corrective measures shall be taken. Such may include the installation of additional piles, strengthening of bent piles, or
replacement of bent piles or acceptance of bent piles at reduced capacity and at a reduced cost.
A concrete pile shall also be considered defective if a visible crack, or cracks, appears around the entire periphery of the pile, or if any defect is
observed which, as determined by the Engineer, affects the strength or life of the pile.
e) Construction of capping slabs/ beams
The Contractor shall not construct the pile capping slab or beams before the Engineer has confirmed, in writing, that all the relevant load tests
have been completed and the piles have been accepted.

B12.1 PILING
CONTENTS
B12.1.1 SCOPE
B12.1.2 DEFINITIONS
B12.1.3 GENERAL
B12.1.5 MATERIALS
B12.1.8 WORKMANSHIP
B12.1.1 SCOPE
B12.1.2 DEFINITIONS
B12.1.3 GENERAL

B12.1.5 MATERIALS


B12.1.8 WORKMANSHIP

C12.1 PILING
(i) Preamble
centre-line of the trench to the bottom of the specified bedding layer (as applicable). Where no bedding is required it shall be measured to the
underside of the duct or pipe.
4. The length used for trench computations will be the total through-length of a pipe or duct etc. from end to end and no deduction will be made for
manholes or access chambers etc.
5. Wherever volumetric measurement is required, the volume will be computed from the depth determined as indicated in 1. and 2. above and using
the authorised width (W) determined in accordance with the specification.
1. No separate payment will be made for backfilling excess excavations, disposing of surplus material etc. or any other contingent work, unless the
work is specifically specified or ordered.
or services damaged by the Contractor’s activities and for complying with all the requirements of Clause A2.1.3.4 of Chapter 2.
pay items.
6. No separate payment will be made for the hauling of any materials where the material is moved over a distance of less than, and up to, 1,0 km.
C13.1.3 of Chapter 13 - All
applicable items
Excavation of materials A12.1.7.4
C13.1.4 of Chapter 13- All applicable
items

Trial piles, if successful, shall also be paid for under these items.
C12.1.1 Additional foundation investigations provisional sum

A provisional sum is provided in the schedule of quantities to cover the cost of this work.
The work shall be carried out as instructed by the Engineer and shall be paid for in accordance with the provisions of the general conditions of
contract.
C12.1.2 Access and drainage:
C12.1.2.1 Access lump sum
C12.1.2.2 Drainage by pumping or other means lump sum

Access:
The tendered lump sum shall include full compensation for providing access, which, inter alia, shall include constructing temporary banks, artificial
islands and/or cofferdams, their protection, safeguarding and maintenance, draining and keeping dry the working areas and draining the
excavations within the access, and any incidentals in respect of work to be done below standing water.
75 % of the lump sum will be paid when access has been constructed and stability and settlement reliability is proven by appropriate testing. Work
shall comply with environmental constraints. The remaining 25 % will be paid after the access is removed.
Drainage
Payment will be made for this work by way of a lump sum for each structure or series of structures appearing separately in the schedule of
quantities. This lump sum shall be paid on a pro rata basis as work progresses.
The tendered lump sum shall include full compensation for draining by pumping or in any other way and for any other work necessary for keeping
excavations dry or for working in the dry.
C12.1.3 Establishment on site for piling (piling locations indicated (type indicated) lump sum
The tendered lump sum shall include full compensation for establishment and subsequent removal of all special construction plant and equipment
for piling as specified, structural platforms, rafts as may be required, general levelling of the sites and for carrying out operations, the cost of which
does not vary with actual amount of piling undertaken on the indicated locations on the project.
The work will be paid by a lump sum, 50 % of which will become payable when all the equipment is on site and the first production pile installed.
The second instalment of 25 % of the lump sum will be payable after half the total number of piles are installed, and the final instalment of 25 %
after all the piles are completed and the equipment is removed from the site.

C12.1.4 Moving to, and setting up equipment at each position for installing piles (pile type number (No)
indicated)
The unit of measurement shall be the number of positions to which installation equipment is moved and set up in position. The quantity measured
shall be the number of piles installed as instructed by the Engineer, including trial and test piles as specified or piles re-driven on the instruction
of the Engineer.
The tendered rate shall include full compensation for all costs involved in the moving and setting up of equipment.

Augered or bored holes (type specified) for piles with a diameter of (diameter indicated)
C12.1.5
through material situated within the following successive depth ranges
C12.1.5.1 Augered holes
(a) 0 m up to 10 m provided for in pay item C12.1.6 metre (m)
(b) Exceeding 10 m and up to 15 m metre (m)
(c) Etc in increments of 5,0 m depths metre (m)
C12.1.5.2 Bored piles
(a) 0 m up to 10 m metre (m)
(b) Exceeding 10 m and up to 15 m metre (m)
(c) Etc in increments of 5,0 m depths metre (m)

Limits for successive depth ranges shall be measured down from agreed average ground surface (Clause A12.1.7.4) to the founding level (Clause
A13.1.7.3 c) of Chapter 13).
The unit of measurement shall be the metres of hole formed, including the depth of bulbous base formed, as may be applicable. The depth of the
bulbous base shall be deemed to be equal to the diameter of a sphere, the volume of which shall be equal to the quantity of compacted concrete
in the bulbous base. Irrespective of the depth of the hole, the quantity within each depth range shall be measured and paid for separately.
The tendered rates for forming augered holes shall include full compensation for augering and disposing of surplus material resulting from hole-
formation.
The tendered rates for forming bored holes shall include full compensation for boring, supplying, installing and extracting driven temporary casings
as well as for disposing of surplus material resulting from hole-formation.

Extra over item C12.1.5 irrespective of the depth, to form augered and bored pile holes
C12.1.6
through identified materials consisting of:
C12.1.6.1 Coarse gravel with a matrix content of less than (max. percentage indicated) metre (m)
C12.1.6.2 Boulders (description of and maximum size indicated) metre (m)
C12.1.6.3 Rock formation (description and class of rock indicated) metre (m)
The unit of measurement shall be the metre of pile hole formed through identified materials, measured from depth at which the identified material
is first encountered to depth at which normal auger drilling or boring may be resumed or another type of identified material is encountered.
The tendered rates shall include full compensation for all additional work and incidentals required for forming pile holes through identified materials.
Notes:
Item C12.1.6.1: The matrix content indicated shall be percentage by volume of matrix in material containing coarse gravel. Where the maximum
percentage indicated is exceeded, payment for forming holes through such material shall be made under item C12.1.5. Unless otherwise specified,
the maximum percentage of matrix shall be 60 %.
Where materials other than those provided for in item C12.1.6 are identified, they shall be described on drawings and/or in Contract
Documentation. Provision therefore shall be made in the schedule of quantities under extensions to item C12.1.6.

C12.1.7 Driving temporary casing for driven displacement piling systems (system indicated) for
forming holes for piles with a diameter of (diameter indicated) through material situated
within the following successive depth ranges:
C12.1.7.1 0 m up to 10 m metre (m)
C12.1.7.2 Exceeding 10 m and up to 15 m metre (m)
C12.1.7.3 Etc in increments of 5,0 m depths metre (m)

The unit of measurement shall be the metre of hole plus depth of the bulbous base formed, as may be applicable
Limits for successive depth ranges shall be measured down from the average ground surface (Clause A12.1.7.4) to the agreed founding level
(Clause A12.1.7.4). The depth of the bulbous base shall be deemed to be equal to be the diameter of a sphere, the volume of which shall be equal
to the quantity of compacted concrete in the bulbous base. Irrespective of total depth of hole, the quantity within each depth range shall be
measured and paid for separately.
The tendered rates shall include full compensation for supplying, driving and subsequently extracting the temporary casing.

provisional
C12.1.8 Forming augered or bored pile holes through unidentified materials
sum
A provisional sum is allowed in the schedule of quantities for covering the cost of this work as approved by the Engineer.
Payment for the work authorised by the Engineer shall be in accordance with the provisions of the general conditions of contract.

provisional
C12.1.9 Forming augered or bored pile holes through obstructions
sum
A provisional sum is allowed in the schedule of quantities for covering the cost of this work as approved by the Engineer.
Payment for the work authorised by the Engineer shall be in accordance with provisions of the general conditions of contract.
C12.1.10 Provision for and maintenance of bentonite head for underslurry piles Lump Sum
The tendered lump sum shall include full compensation for supplying the bentonite, for all equipment for mixing pumping, de-sanding and all other
operations required to complete the task

C12.1.11 Installing and removing temporary casings in augered holes for metre (m)
piles of (diameter indicated)
The unit of measurement shall be the metre of temporary casing installed as directed by the Engineer or shown on the drawings. Only installed
temporary casing below the average ground surface (Clause A12.1.7.4) shall be measured for payment.
The tendered rate shall include full compensation for supplying, installing and removing the temporary casings.

metre (m)
C12.1.12 Installing permanent pile casing for piles of (diameter and pile type indicated)
The unit of measurement shall be the metre of permanent casing installed as instructed by the Engineer or shown on the drawings.
The tendered rate shall include full compensation for supplying and installing permanent pile casing.
C12.1.13 Extra over items C12.1.5 and v C12.1.7 for raking of piles:
C12.1.13.1 Holes for piles of (diameter and rake indicated) metre (m)
metre (m)
C12.1.13.2 Temporary casing for driven displacement pile systems (diameter and rake indicated)
The tendered rates shall include full compensation for all additional work and incidentals for forming pile holes or for driving and later extracting
of temporary casing.
C12.1.14 Forming bulbous bases for piles of (diameter indicated) number (No)
The unit of measurement shall be the number of bulbous bases formed.
The tendered rate shall include full compensation for all work conducted in forming the bulbous bases but shall exclude the concrete work.
C12.1.15 Steel reinforcement in cast in situ piles:
C12.1.15.1 Mild-steel bars (type indicated) ton (t)
C12.1.15.2 High-yield-stress-steel bars (type indicated) ton (t)

The unit of measurement for steel bars shall be the tonne of reinforcement in place in accordance with drawings or as may have been authorised.
Ties and other steel used for keeping reinforcing steel in position shall be measured as steel reinforcing under appropriate subitem.
The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding, trial welds, placing and fixing steel
reinforcing, including all tying wires, spacers and waste.

C12.1.16 Cast in situ concrete in piles, underreams, bulbous bases and sockets (class of cubic metre (m3)
concrete indicated)
The unit of measurement shall be the cubic metre of concrete placed in the cast in situ piles, under-reams, bulbous bases and sockets. The
quantity shall be calculated from the nominal pile diameter and the length of pile from founding level to specified cut-off level, plus additional
quantity of concrete in the bulbous bases as may be relevant.
The tendered rate shall include full compensation for supplying and storing all material, providing all plant, mixing, transporting, placing and
compacting the concrete as well as the curing of the concrete. Payment shall distinguish between different classes of concrete.
C12.1.17 Extra over item C12.1.16 for concrete cast underwater cubic metre (m3)
The unit of measurement shall be the cubic metre of concrete cast under water, the quantity being calculated as for item C12.1.16.
The tendered rate shall include full compensation for all additional work, incidentals and extra cement required for placing the concrete under
water.

metre (m)
C12.1.18 Manufacturing, supplying and delivering prefabricated piles (type and size indicated)
The unit of measurement shall be the metre of accepted prefabricated pile delivered on site in accordance with the Engineer's written instructions.
The tendered rate shall include full compensation for supplying all materials, the manufacturing, transporting and delivering to the point of use and
handling of the prefabricated piles.

Installation of prefabricated piles (type and size indicated) through material situated
C12.1.19
within the following successive depth ranges:
C12.1.19.1 0 m up to 10 m metre (m)
C12.1.19.2 Exceeding 10 m and up to 15 m metre (m)

Limits for the successive depth ranges shall be measured down from average ground surface (Clause A12.1.7.4) to the agreed founding depth
(Clause A13.1.7.3 c)).
The unit of measurement shall be the metre of prefabricated pile installed. That part of the prefabricated pile projecting above the average ground
surface shall not be measured and paid for. Irrespective of total length of pile installed, the quantity installed within each depth range shall be
The tendered rates shall include full compensation for hoisting and driving the pile.

Installation of self-drilling micropiles (size indicated) through material situated within
C12.1.20
the following successive depth ranges:
C12.1.20.1 0 m up to 9,0 m metre (m)
C12.1.20.2 Exceeding 9,0 m and up to 15 m metre (m)

Limits for the successive depth ranges shall be measured down from the average ground surface (Clause A12.1.7.4) to the agreed founding depth
(Clause A13.1.7.3 c)).
The unit of measurement shall be the metre of micropile installed as specified. That part of the micropile projecting above the average ground
surface shall not be measured and paid for. Irrespective of the total length of pile installed, the quantity installed within each depth range shall be
The tendered rate shall include full compensation for supplying all materials, personnel and equipment required for the installation of the micropiles

C12.1.21 Driving temporary casings for driven displacement in piling systems or install provisional
prefabricated piles through identified or unidentified materials sum
A provisional sum is allowed in the schedule of quantities for covering cost of this work. The method of payment for work authorised by the
Engineer shall be in accordance with provisions of the general conditions of contract.

C12.1.22 Extra over item C12.1.19 for raking of prefabricated piles (type, size and rake indicated) metre (m)
The unit of measurement shall be the metre of pile installed.
The tendered rates shall include full compensation for all additional work and incidentals for installing prefabricated piles to specified rakes.
C12.1.23 Splicing/coupling prefabricated piles for lengthening (size of pile indicated) number (No)
The unit of measurement shall be number of splices/couplings in prefabricated piles for each size of pile.
The tendered rate shall include full compensation for all work required for splicing/coupling piles in accordance with the specifications.
C12.1.24 Stripping/cutting the pile heads (type and diameter/size of pile indicated) number (No)
The unit of measurement shall be the number of heads of each type and diameter/size of pile stripped/cut.
The tendered rate shall include full compensation for providing all tools and stripping/cutting pile heads.
C12.1.25 Establishment on site for the load testing of piles lump sum
The tendered lump sum shall include full compensation for the establishment on site and subsequent removing all special plant and equipment
required for conducting load tests on piles as specified. This cost does not vary with the number of load tests to be conducted. Payment for this
work shall be made by way of a lump sum, 100 % of which will be paid after testing assembly is completely assembled and the first load test
started. Standing time will not be paid in respect of piling activities and for pile installation equipment while pile testing is being carried out and the
results thereof are being assessed.

C12.1.26 Load tests on piles (compression/tension test, diameter/ size, specified, working load and number (No)
pile type indicated)
The unit of measurement shall be the number of load tests conducted on instruction of Engineer, for each specified working load. Test piles shall
be measured as specified above as for permanent piles. Anchor piles and anchors shall be deemed to form part of the testing equipment and
shall not be measured under this item.
The tendered rate shall include full compensation for installing anchor piles and anchors where necessary; conducting load tests, and the
processing and submitting of results.
C12.1.27 Establishment on site for core drilling lump sum

The tendered lump sum shall include full compensation for the establishment on site and subsequently removing all plant and equipment required
for conducting specified core drilling. This cost does not vary with quantity of work to be done. This work will be paid by way of a lump sum, 75 %
of which will become payable when all the equipment is on site and the first hole completed. The remaining 25 % will become payable after all the
holes are complete and the equipment is removed from site.
C12.1.28 Moving equipment to and assembling at each location where cores are to be drilled number (No)
The unit of measurement shall be number of locations to which core-drilling equipment is moved and at which it is assembled.
The tendered rate shall include full compensation for cost of moving and assembling equipment.
C12.1.29 Drilling the cores (diameter indicated) in:
C12.1.29.1 Concrete metre (m)
C12.1.29.2 Founding formation:
(a) Irrespective of hardness metre (m)

The unit of measurement shall be the metre of hole drilled.
The tendered rate shall include full compensation for drilling, core recovery, sheathing and the packing of the cores, provision of drilling records,
providing core boxes, providing and installing casings, and backfilling the holes with grout.
C12.1.30 Standing time for pile-installation frame hour (h)

The unit of measurement for standing time of a pile-installation frame shall be the hour during which the pile-installation frame is standing.
The tendered rate shall include full compensation for all fixed costs for the pile-installation frame, which is not connected with its operation and
quantity of work done.
C12.1.31 Pile Integrity Testing on augered/bored piles

C12.1.31.1 Providing and installing (diameter indicated) mild steel metre (m)
tubes for “Cross Hole Sonic Logging” in all designated piles
C12.1.31.2 Carrying out of Impact Frequency Response (IFR) measurements or Sonic Tapping tests number (No)
and interpretation of results (per pile diameter)
C12.1.31.3 Cross-Hole Sonic Logging tests and interpreted results (per pile diameter) metre (m)
C12.1.31.4 Base integrity tests (per designated pile) number (No)
The unit of measurement for C12.1.31.1 for the 85 mm nominal diameter mild steel tubes shall be the metre of approved 3,0 mm thick tubes provided
and installed into all designated piles of various diameters in accordance with the specification.
The tendered rate shall include full compensation for all materials, plant and equipment required or the installation of the tubes in the designated piles
as specified
The unit of measurement for C12.1.31.2, Impact Frequency Response tests shall be the number of designated piles tested by the IFR method
The tendered rate shall include full compensation for the establishment on site, procurement, preparation, conducting and supervising the tests and
full compensation for the proper evaluation and reporting of the results and findings of the IFR consultant to the Engineer,
The unit of measurement for C12.1.31.3, CSL tests, shall be the metre of pile shaft fully tested (for all designated piles) using the Cross-Hole Sonic
Logging method.

The tendered rate shall include full compensation for establishment and removal of all specialised equipment and expert personnel as well as for all
materials, the preparation, execution and supervision of the testing as well as for evaluation and reporting of the results, the interpreted
findings/conclusions/recommendations of the CSL consultant to the Engineer.
The unit of measurement for C12.1.31.4, Base integrity testing shall be the number of base integrity tests performed as described in Clause
A12.1.8.4b) as instructed by the Engineer.
The tendered rate shall include logging of cores and the grouting up of all CSL tubes after successful testing. The drilling of cores through pile
concrete and founding formation (irrespective of hardness) shall be paid for under item C12.1.28,
Establishment on the site for core drilling in piles for the installation of tubes for Cross Hole Sonic Logging shall be paid under pay item C12.1.27
while moving equipment and assembling it at each location/pile position where cores are to be drilled shall be paid under pay item C12.1.28

Lateral support to
C12.1.32
excavations
C12.1.32.1 At location (to be indicated):
(a) 0 to 3,0 m depth square metre 2
(b) 3,0 to 6,0 m depth square metre 2
C12.1.32.2 At other locations (As indicated) square metre 2

The unit of measurement shall be the square metre of excavated face supported over the successive depth ranges, measured down from the
agreed ground level.
The tendered rate shall include full compensation for procuring and installing the lateral support system, as well as for removal, if required. It shall
include for all materials, labour, plant, equipment and incidentals to provide support to the excavated faces for the duration of substructure
construction.
The cost of excavating the material shall not be included but paid for under items C13.1.3 and C13.1.4 of Chapter 13.

D12.1 PILING
CONTENTS
D12.1.1 SCOPE
D12.1.2 GENERAL
D12.1.1 SCOPE
The scope of this Section covers the following:
- Guarantees and compliance certificates
- Product conformance specifications
D12.1.2 GENERAL
The Contractor shall provide detailed specifications, test data, performance data and compliance certificates from independent reputable agencies
for all proprietary systems, processes and materials proposed for use. These shall demonstrate conformance with the performance requirements
specified in the Contract Documentation. Unless otherwise specified, all proprietary materials shall be used and placed in strict accordance with
the relevant manufacturer's current published instructions

The Contractor shall, within 28 days of entering into the contract with the Employer, submit to the Engineer conformance documentation related
to the specifications.
Conformance documentation shall be provided for the following:
- Materials and Materials Design as per Clause A12.1.3.2
- Materials as per Clause A12.1 5,
- Construction Equipment as per Clause A12.1.6
- Execution of the Works as per Clause A12.1.7








12.2 GROUND ANCHORS
CONTENTS
A12.2.1 SCOPE
A12.2.2 DEFINITIONS
A12.2.3 GENERAL
A12.2.5 MATERIALS
A12.2.8 WORKMANSHIP

A12.2 GROUND ANCHORS

A12.2.1 SCOPE
This Section covers the design, supply, installation, stressing and testing of cable and rigid anchors.
A12.2.2 DEFINITIONS
Cable anchor - is a generic term covering all types of wire-strand cable ground anchors which are generally subdivided into rock anchors and
soil anchors. It is an installation which is capable of transmitting an applied tensile load to a stable load bearing stratum. The installation generally
consists of a stressing anchorage, a tendon with an uncoupled/free length and an anchored/ fixed length in the load bearing stratum.
Temporary anchor / Rockbolt / Soil nail / Dowel - installations used during the construction phase of a project to provide support for the period
until the permanent works are in place.
Test Anchor - is an anchor installed according to the Contractor’s proposed method statements whereby the Contractor shall demonstrate both
the suitability of the plant and equipment, the design of the anchors as well as their competency to install the anchors as designed and specified.
The term ‘test anchor’ shall include ‘proving’, ‘trial’ and ‘site suitability’ anchors as referred to elsewhere in this specification and other supporting
documents referred to.
Deadman Anchor - are anchors that have anchorages at both ends of the tendon or bar. One end of the anchor may be permanently fixed into
an anchor block which generally will be buried during construction or may be a retaining structure/element allowing tensioning to be carried out
from the other end. Other types have anchorages at both ends allowing tensioning from either end.
Permanent Anchor / Rockbolt / Soil Nail / Dowel - an installation required to ensure the stability and satisfactory performance of the permanent
works being supported.
Stressing Anchorage - is a component of a ground anchor capable of transferring the tensile load from the tendon to the surface of the ground
or structure requiring support:
- Normal type - An anchorage designed to permit the load in the anchor tendon to be raised or lowered within the entire range of operating
stress levels and measured when necessary to meet the requirements of acceptance testing. This is only possible during the initial stressing
phase as protruding tendons are cut making further measurement or adjustment impossible.
- Re-stressable type - An anchorage meeting all the requirements of the normal anchorage and permitting the load on the anchor tendon,
throughout the life of the support structure, to be measured by check lifting. It also allows small losses of up to 10 % of the working load to
be recovered.
- De-tensionable type - An anchorage meeting all the requirements of the re-stressable type and in addition permitting the anchor tendon to
be de-tensioned in a controlled manner at any time during the life of the anchor.
Fixed Anchor Length - is the designed length of the anchor over which the tensile load is transferred to stable load bearing strata.
Free Anchor Length - is the design length between the proximal end of the fixed anchor length and the stressing anchorage.
Proximal End - is nearest to the stressing anchorage or collar head.
Distal End - is furthest from the stressing anchorage or collar head.

Anchor Jacking End - the jacking end of the anchor is defined as the concrete bearing pad and the steel thrust plate.
Anchor Tendon - is that part of the anchor which transfers the tensile load from the fixed anchor to the stressing anchorage. Tendons can
comprise single 7 wire strands or multiples thereof.
Anchor Tendon Bond Length - is the length of the anchor tendon which is bonded directly to the encapsulating grout within the fixed anchor
length.
Capsule Bond Length - is the overall length of the outer perimeter of the capsule within the fixed length which is bonded to the surrounding
homing grout.
Fixed anchor length - the length of tendon/ anchor over which the tensile load is transmitted to the surrounding ground.
Tube- a- manchette - comprises single or multiple holes provided in a discrete section of a high pressure grout tube tightly sheathed with plastic
tubing which allows the outward passage of grout under high pressure.
Anchor assemblage - comprises the tendon, in its corrugated sheathing, complete with spiralled external grout pipes
Calculated Free Tendon Length - the calculated length of the anchor tendon is the length of tendon at the point at which it effectively bonds with
the encapsulating grout in the fixed length once it is stressed. This can only be determined during the initial stressing operation from load extension
tests. The nominal free anchor tendon length may be extended by the stressing length depending on the type of stressing system employed.
Homing Grout - the grout injected before or after tendon homing, and prior to stressing.
Primary Grout - the grout injected to secure the fixed length of the anchor within the sheath. The Contract Documentation may allow for the
grouting of the free length under this operation or may specify that the free length only be grouted on the successful completion of the stressing.
High Pressure Grout - secures the fixed length to the surrounding stable strata.
Secondary Grout - is the grout injected after stressing to bond and/or protect the free length of the tendon where post stressing grouting of the
free length is specified in the Contract Documentation.
Lift-Off Load - is the minimum load monitored during a stressing or load checking operation which provides a defined clearance, typically 0,1 mm
– 1,0 mm, between the anchor head or ring nut and the anchor plate.
Relaxation - is the decrease of load in the tendon over time.
Creep - is the movement of the fixed length, with time, under load.
Skin Friction - is the bond value at the ground/grout interface over the fixed anchor length.
De-bonding - is the breakdown of bond at the grout/tendon or ground/grout interface.
Decoupling - is the separation of tendons over the free length from the surrounding ground and/or grout, via greased sheathing.
Characteristic Strength - the value of cube strength of grout or concrete or the ultimate tensile strength of the steel in the wire strand, below
which not more than 5 % of the test results fall.
Rigid Anchors - is a generic term covering all types of generally non flexible anchors including rock dowels, rockbolts and soil nails.
Rock Dowel - is a generic term covering all types of steel bars and/or polymeric rods in rock which are fully bonded and untensioned.
Rockbolt - is a generic term covering all types of steel bars and/or polymeric rods in rock which are partially or fully bonded and tensioned.
Soil Nail - is a generic term covering steel bars and/or polymeric rods in soil which are fully bonded but generally untensioned.
Bolting - describes the drilling of holes by means of percussion or hydraulic equipment in rock and the subsequent insertion and grouting or
mechanical anchoring of steel bars within these holes. Face plates, washers/spacers and nuts are generally secured to the protruding end of the
bolts which are provided with a thread.
Soil Nailing - as for bolting but inserted into soil and/or highly/completely weathered or friable rock.
Self-Drilling Anchors - are hollow stem anchors provided with sacrificial drilling bits with grout introduced concurrently through the stem so that
the grouting is completed on drilling of the anchor. The sacrificial drilling bit must be capable of drilling through obstacles such as concrete and
rock boulders and capable of intersecting rock if required.
Anchor Head Protection - serves to both protect the bolt head and face plate against vandalism / corrosion and to camouflage it so that it blends
in with the surrounding ground surface.
Driven Tipping Anchor - describes all types of anchors first driven into soil and then pulled back to engage the tipping anchoring mechanism.
Pre-drilling may be required before driving in competent formations such as very soft rock and/or stiff/dense soils.
Screw Anchor - describes all types of screw and helical earth anchors. They shall be used in soil only.
A12.2.3 GENERAL
shall, however, remain responsible for all work-methods, materials, plant and equipment used, notwithstanding acceptance by the Engineer.
The Contractor shall be required to construct test or trial anchors and the testing thereof as specified herein and shall make due allowance
therefore in his programme. Allowance shall also be made for allow for the Engineer’s assessment of constructed anchors, procedures followed,

and materials and plant utilised and test data. Production anchoring shall not be permitted until it is shown and accepted by the Engineer that the
Contractor possesses the necessary experience, plant and equipment to carry out the works as specified in the Contract Documentation.
A12.2.3.2 Materials and materials design approvals

related to the specifications, test results as required together with samples of materials and where applicable, materials designs that he proposes
to use in the construction of the works to the Engineer for his acceptance/approval as provided for in the Contract Documentation.
The Contractor’s attention is drawn to the approvals required as indicated in Table A12.2.3-1 below regarding works carried out under this section
of the works:
Table A12.2.3-1: Required Approvals
Clause Requirements Period
Materials Design Approvals
Design for the homing, encapsulation and high pressure 4 weeks before trial anchor
A12.2.5.1b)
grout construction
Materials approvals
4 weeks before the approved
Samples, prototypes and technical details of the proposed
A12.2.5.1b) programmed trial/test anchor
anchoring materials
construction activity.
Full details of the tensioning system(s), materials and 4 weeks before the approved
A12.2.6.1d) equipment, and methods to be adopted in tensioning and programmed trial anchor
related operations construction activity
Construction Approvals
Two weeks prior to commencement
A12.2.7.2 a) Construction Method Statement for trial/test cable anchors
of trial/test anchor installations
Four weeks after Engineer’s
Construction Method Statement for working/production
A12.2.7.2 a) approval of the installation and test
cable anchors
results
One week after Engineer’s approval
A12.2.7.2 a) Installation of working/production cable anchors
of Construction Method Statement
Two weeks prior to commencement
Construction Method Statement for trial/test rock bolts/ soil of trial/test rock bolt/ soil nail
A12.2.7.3 b) installations
nails
4 weeks prior to commencement of

Contractor’s Construction Method Statement for rock any permanent rock bolting / soil
A12.2.7.3 b) nailing.
bolting / soil nailing
Engineer’s approval of Construction

A12.2.7.3 b) Installation of working rock bolts/ soil nails Method Statement for production
rock bolts/ soil nails
A12.2.3.3 Additional requirements

The works in this section comprise the design, manufacture, installation, tensioning, testing, protection and the performance monitoring of cable
anchors, soil nails, rockbolts and mechanical earth anchors for the application as described in the Contract Documentation. The works are of a
highly specialised nature and shall only be carried out by Contractors who have the necessary experience, expertise, plant and equipment, to
carry out the works as specified. The CV’s of all key personnel shall be submitted for approval by the Engineer.
• Unless otherwise specified in the Contract Documentation all ground anchors shall be designed and constructed in compliance with these
specifications and in compliance with the following standards/codes of practice:
- Lateral Support in Surface Excavations: Code of Practice 1989: SAICE.
- Execution of Special Geotechnical Works-Ground Anchors; BS EN 1537: 2013.
- British Standard Code of Practice for Ground Anchorages; BS 8081: 2015
- BS EN 14490:2010. Execution of Special Geotechnical Works- Soil Nailing
The installation of working cable anchors, soil nails or rockbolts or mechanical earth anchors shall only commence when the Engineer has given
his written acceptance of the designs for which the Contractor is responsible in terms of the Contract Documentation, the Contractor’s method
statements, the proposed materials, the proposed drilling methods and of the Contractor’s successful installation and testing of the trial anchors/
soil nails/rockbolts.

The Contractor shall, unless otherwise indicated in the Contract Documentation, be responsible for the design of the ground anchors to meet the
performance requirements specified by the Engineer. The Contractor shall similarly be responsible for the design of all grout, concrete and/
specialised cementitious products required for the installation and protection of the ground anchors.
The following shall be applicable in this regard:
• The ground anchors shall be designed in compliance with these specifications and in addition, the following in the order of precedence
shown, unless specified otherwise by the Engineer:
- Lateral Support in Surface Excavations: Code of Practice 1989: SAICE.
- Execution of Special Geotechnical Works-Ground Anchors; BS EN 1537: 2013.
- British Standard Code of Practice for Ground Anchorages; BS 8081: 2015
- BS EN 14490:2010. Execution of special geotechnical works. Soil nailing
• The Engineer shall specify the following design criteria:

- Sequencing of the works in the event that it impacts on the design
- Whether the anchors are permanent or temporary
- Working load
- Class and type of anchor
- Corrosion protection
- Minimum free length
- Minimum fixed anchor length
- Inclination
- Directional tolerances
• The following geotechnical information will be provided to the Contractor:
- Rock or ground Engineering characteristics
- Borehole logs and cores for inspection
- All other pertinent factual geotechnical information as may be available
The Contractor shall in carrying out his design obligations, familiarise himself with the available information and shall, at his own cost, carry out
whatever further investigations are required. This aspect must be catered for in the programme. In carrying out these obligations the Contractor
shall take note of the following:
- No cable anchor may be installed closer than 1,0 m from any point on the exterior of a known service, service duct or culvert.
- The anchors shall be designed such that the working stress in the tendons does not exceed 53% of the characteristic breaking stress for
permanent anchors and 64 % for temporary anchors.
- The Contractor shall assess the suitability of the bursting reinforcement in the concrete bearing pad to ensure that it is compatible with the
stressing system he intends using and will efficiently transfer and maintain the anchoring forces. Allowance shall be made by the Contractor
for any additional reinforcement required for the anchorage of his anchors. Payment for this additional reinforcement shall be deemed to be
included in the rates for the anchors.
- Test and/or site suitability anchors shall be carried out to the Engineer’s requirements and as specified in the Contract Documentation.
- The Contractor may not commence with the manufacture and installation of ground anchors until the Engineer has given written approval of
the Contractor's design.
A12.2.5 MATERIALS
All elements subject to hot dip galvanising shall be treated in accordance with SANS 121/ISO 1461 to a mean coating thickness of 85µm and
thereafter passivated using a non-toxic approved product.
A12.2.5.1 Materials for cable anchors

a) General
All materials used in the ground anchors shall comply with the requirements of Clause A13.5.5 of Chapter 13 and all equipment used in the
fabrication, grouting and stressing shall comply with the requirements of Clause A13.5.6 of Chapter 13.
All materials shall also comply with the following additional requirements:
The tendons shall be manufactured from class1 relaxation high tensile non-alloy 7-wire strand with a nominal tensile strength of 1 770 MPa or
multiples thereof in accordance with BS 5896 (2012). The sheathing and injection of the grease into the annulus between the strand and the
sheathing shall all be performed during the course of manufacture, and the grease shall comply with the requirements given in Table A12.2.5-1
for rust-inhibiting properties. The minimum thickness of the sheathing shall be 1,0 mm.
Each batch of strand delivered to site shall be accompanied by a test certificate issued by a recognised accredited testing authority specifying the
characteristic strength of the strand, plus a proof stress/strain diagram reflecting a test on a sample of the strand from that particular batch of
manufacture, indicating the 0,1 % and 0,2 % proof stress.
Prestressing steel shall be clean, free from faults or defects, and without any harmful films and matter which may impair adhesion to the grout or
concrete. The sheathing shall be free of any holes, cuts or abrasions through which the injected grease may escape. Deficient strands will be
rejected. Strands damaged in removing the sheathing on the fixed length or on the working length shall similarly be rejected.
b) Cementitious grout
Cement grout shall be manufactured using the cement as specified in the Contract Documentation. CEM1 42.5 or as otherwise approved using
potable water, with or without additives with a water/cement ratio ranging from 0.35 to 0.70. For anchorages installed in low permeability ground,
i.e. rock or clay, the water/cement ratio should not exceed 0.45. The use of additives shall be subject to the Engineer’s approval and demonstrated
performance in the testing of the grout.

Bleeding at 20C measured in accordance with Clause A20.1.5.6b)(iv) of Chapter 20 shall not exceed 2 % by volume 3 hours after the grout has
been mixed, and the maximum bleeding shall not exceed 4 %. In addition, the separated (bleed) water must be reabsorbed after 24 hours.
The Contractor shall submit the design for the homing, encapsulation and high pressure grouting to the Engineer together with samples of all the
constituents four weeks before the commencement of trial anchor installation together with the test results indicating the 7 and 14 day strengths
obtained using the mix. At least two sets (3 cubes each) shall be presented on the prescribed form. The mixing, manufacture, curing and testing
of the cubes shall be carried out by an approved, SANAS accredited laboratory facility in terms of their accredited tests. The cube compressive
strength of 100 mm cubes made of the grout and cured in a moist atmosphere for the first 24 hours and then in water at 20°C shall exceed 20
MPa at 7 days. Sampling and testing of anchorage grout will be required as specified in Clause A12.2.8.1a).
The consistency of each batch of grout shall be tested with the flow cone and any variation exceeding 20 % of the average daily recorded shall
be immediately brought to the attention of the Engineer.
c) Water
Water for grout shall comply with SANS 241.
d) Corrugated sheathing
The fixed anchorage length of the anchor shall be encapsulated in a corrugated high-density polyethylene, polypropylene or similar approved inert
sheathing, of 1,0 mm minimum wall thickness. The pitch of the corrugations shall be within six to twelve times the sheath wall thickness and the
amplitude of corrugations not less than three times the wall thickness. Alternative profiles may be offered but “curved” corrugations are preferred
to the “square” type. The internal diameter of the corrugated sheathing shall provide a minimum cover of 10 mm between the strand and the
corrugated sheathing. If the anchor design provides for the corrugated sheathing to be extended over the free length as well as the fixed anchorage
length, this sheathing shall comply with the same requirements as those for the fixed anchorage length, and will continue, preferably without
jointing up the full length of the tendon.
If it becomes necessary to join two sections of corrugated sheathing, such joints shall be sealed to occlude the passage of fluids. The Contractor
shall demonstrate this and obtain the Engineer’s approval before employing such sheathing on working anchors.
e) Grout tubes
The grout tubes shall have a minimum external diameter of 20 mm and sufficient internal diameter to allow for the insertion of a washing tube.
The tubes shall have sufficient capacity to cater for the grouting pressures to which they will be subjected. The tubes shall have a spare capacity
of at least 20% above that of the highest pressure required to successfully grout the fixed length of the anchors.
f) Tube-a-manchettes
The grout tubes required for the tube-a-manchettes shall cater for the very high pressures which may be required to create appropriate anchorages
for the given ground conditions over the fixed length. Manchettes shall be provided at no greater spacing than 750 mm along the fixed anchorage
length to enable re-injection of this portion of the anchor to be performed. These manchettes will be required for all ground anchors. The end of
the high pressure injection tube shall be fitted with a clamp, valve or device capable of withstanding the maximum pressures that it shall be subject
to plus 10 %, without loss of grout.
g) Anchor heads and pull bars
Anchor heads shall unless otherwise specified in the Contract Documentation, be of the re-stressable type, such that monitoring of the residual
load in the anchor and re-tensioning can be carried out. Anchorages and couplers shall comply with BS EN 13391. They shall be capable of
sustaining twice the working load with an angular deviation of not more than 5° from the tendon axis and without excessive distortion.
The anchor head and proposed pull bar should be compatible and shall have been tested by a competent instance to withstand twice the required
loads.
The Contractor shall submit samples and technical details of the proposed anchor heads as well as details of the pull bar to the Engineer for his
acceptance at least 4 weeks before the intended use. The pull bar details shall include Engineering drawings that can be used for the manufacture
of replacement pull bars by others. If so specified the pull bar used shall remain the possession of the Employer.
h) Wedges
Wedges shall comply with BS EN 13391.The Contractor shall submit samples and technical details of the wedges to the Engineer for approval at
least 4 weeks before the intended use.
i) External centralisers
External centralisers to the corrugated sleeve may consist of a solid polyethylene core, with an external diameter not less than 10mm, wrapped
in a spiral in order to centralise the entire anchor assembly.
If the spacer system around the corrugated sheathing is intended to take the form of a helically wrapped tube, which also functions as an injection
tube, this tube shall not be smaller than 20 mm diameter and the pitch of the helix shall not be greater than 1 m. The Contractor shall submit
samples and technical details of the centralisers to the Engineer for approval at least 4 weeks before the intended use.
j) Tendon spacers / centralisers
Tendon spacers/ centralisers shall be provided over the full length of all tendons or encapsulations to ensure tendon centralisation, spacing and
separation of the components to achieve effective grout penetration and a minimum grout cover of 10 mm. The spacer shall be designed to provide
a clear spacing between individual tendon components of not less than 5,0 mm.
Tendon spacers / centralisers to retain the strands shall be located at no greater distance than 1,5 m centre to centre and shall be of an approved
type capable of carrying the mass of the tendon without deflection, distortion or compression. The design of these centralisers shall be such to
permit the smooth flow of grout and avoid the formation of pockets of water or air adjacent to them. The Contractor shall submit samples and
technical details of the centralisers to the Engineer for approval at least 4 weeks before the intended use.

k) Shims
All shims shall be manufactured from grade 300W mild steel and be suitably machined to ensure a uniform, even bearing surface. The shape
shall facilitate easy installation and extraction. The Contractor shall submit samples and technical details of the shims to the Engineer for approval
at least 4 weeks before the intended use.
l) Anchor head covers
The anchor head covers shall be compatible with the approved anchor heads and shims, provide 50-year corrosion-resistance and be vandal
proof. They shall be filled with grease, complying with BS 8081.
The covers shall be fitted with suitable gaskets and shall be coupled to the anchor thrust plates securely to avoid grease loss. Covers leaking
grease shall immediately be replaced, re-greased all at the Contractor’s expense.
The Contractor shall submit samples and technical details of the anchor head covers to the Engineer for approval at least 4 weeks before the
intended use.
m) Anchor thrust plate
The steel thrust plate shall be manufactured to the dimensions indicated in the Contract Documentation and on the drawings. Unless otherwise
specified the thrust plates shall be hot dip galvanised in accordance with SANS 121 /ISO4998, with a minimum mean coating thickness of 85µm.
The Contractor shall submit samples and technical details of the anchor thrust plate to the Engineer for approval at least 4 weeks before the
intended use.
n) Anchor component compatibility
A prototype shall be assembled where appropriate and the complete anchor system presented for inspection.
o) Grease
Grease shall comply with the requirements in Table A12.2.5-1 for rust-inhibiting properties.
Table A12.2.5-1: Properties for rust inhibiting grease
PROPERTY UNIT METHOD REQUIREMENTS
ASTM D127
Drop point (OC) 0
C ASTM D 566
65 min
ASTM2265/IP396
0 ASTM D92
Flash point C 150 min
ASTM D93
Penetration: un- worked
mm-1 ASTM D217 > 150
@ 25 0 C
Penetration: worked @ 250 C mm-1 ASTM D217 >250< 350
Oxidation stability: Loss in kPa ASTM 942

70 max
@100 hrs
140 max
@400hrs
210 max
@1000hrs
Corrosion resistance/rust test
(visual) ASTM D1743 Pass
14 days@250 C and 100 % rel. hum.
(rating 2)
Salt spray:1,0 mm grease@500 hrs ASTM B117 No corrosion
Acid and Base number mgKOH/g ASTM D974-85 (mod) 0.6 max
Oil separation % ASTM D1742 FTMS791C 3 % max
ISO 11009
Water washout % m/m ≤5
ASTM D1264
ASTM D95
W Water content % m/m <0.1
ISO 3733
Evaporation loss* % m/m ASTM D972-56 0.5 max
ASTM D512
chloride content* ppm 5 max
ASTM D432-7
Nitrate content* ppm, ASTM D432-7 5 max
Sulphide content* ppm ASTM D432-7 5 max
* Recommended limits
p) Cement
The cement used in the manufacture of grout shall be CEM 1 42.5 N unless otherwise specified in the Contract Documentation.
A12.2.5.2 Materials for rockbolts, dowels and soil nails

a) General
All materials used for rockbolt, dowels and soil nails shall comply with the following standards:
SABS 920 – Steel bars for concrete reinforcement
SABS 1024 – Welded steel fabric for concrete reinforcement
SAICE Lateral Support in Surface Excavations: Code of Practice 1989
BS EN 14490:2010. Execution of special geotechnical works- Soil nailing

b) Rockbolts, dowels and soil nails
These shall be steel bars and/or polymeric rods, either solid or hollow stem. The steel bars shall be hot-rolled, deformed, continuously coarse-
threaded high-yield steel (greater than 500 MPa) of specified diameter and length. Steel for hollow-stem self-drilling anchors shall also comply
with EN 10210 (Hot finished structural hollow sections of non-alloy and fine grain structural steels and SANS 920.
Polymeric rock bolts and dowels may be used as specified in the Contract Documentation.
Mechanically end-anchored rockbolts and dowels shall be permitted, including ‘split set’, ‘swellex’ and other types.
c) Steel face plates, washers & nuts
Steel faceplates, hemispherical washers and nuts shall be supplied with each soil nail. All soil nails and face plates nuts and washers shall be
hot dip galvanised in accordance with SANS 121/ISO1461 to a mean coating thickness of 85µm. The soil nails, face plates, nuts and washers
shall thereafter be passivated using a non-toxic approved product. When used in conjunction with wire netting galvanised spike plates may be
specified.
d) Cementitious grout
Only CEM I 42.5 N / CEM II 35.2.N.BV which complies with the requirements of SANS 50197 shall be used unless otherwise specified in the
The temperature of the cement shall be less than 40°C.
Fine aggregate if used in the mix shall consist of siliceous granules, finely ground limestone or very fine sand. It shall all pass a 0,600 mm sieve
and shall be subject to the approval of the Engineer. The aggregate content in the grout shall not exceed 30% of the mass of the cement.
Admixtures shall not be used in the grout without the approval of the Engineer. Admixtures shall be free of any product liable to damage the steel
or the grout itself, such as halides, nitrates, sulphides, sulphates, etc. The amount of admixture to be used shall be in accordance with the
manufacturer’s instructions.
The mixed grout shall have the following properties:
- C1-ions content shall not exceed 750 mg per litre.
- Viscosity will be measured in a standard flow cone or similar approved. Flow shall not be less than 12 seconds and not more than 30
seconds. Any other approved cone shall be calibrated against the standard cone.
- Bleeding at 20°C shall not exceed 2 % by volume, 3 hours after mixing, and the maximum bleeding shall not exceed 4 %. After the initial
grouting of the nails, any bleed shall be compensated for by topping up the hole.
- The compressive strength of 100 mm cubes made of the grout and cured in a moist atmosphere for the first 24 hours and thereafter in water
at 20°C shall exceed 20 MPa at 7 days.
- Grout must be tested on a daily basis.
e) Resin grout
Resin grout shall comply with the recommendations of BS 8081 and prepared and applied in accordance with the manufacturer’s prescription.
f) Water
A12.2.5.3 Materials for tipping anchors

The numerous proprietary products shall comply with the following specifications:
Steel: SANS 920
Iron: SANS 920
Galvanising: SANS 121/ISO1461
A12.2.5.4 Materials for mechanical screw earth anchors

The materials used shall comply with the requirements in the Contract Documentation.

A12.2.6.1 Construction equipment for ground anchors
a) Drilling equipment
The drill rig and equipment shall be in good working order and capable of producing the anchor/bolt or soil nail hole to the required dimensions,
tolerances, direction and inclination without undue disturbance of the surrounding material. Should the type of rig and/or equipment prove
rig/equipment shall be able to install and remove casings as required during drilling operations, without loss of direction or inclination, in all
materials.
b) Grout mixer
The mixer used for the manufacture of grout for anchoring purposes shall be a high shear colloidal mixer. The holding tank shall be fitted with an
agitator capable of maintaining the colloidal condition and fluidity of the mix. The outlet shall be fitted with a suitable filter with openings of less
than 1,0 mm to remove any aggregations.

c) Grout pump
The grout pump shall be a positive-displacement type and shall, unless otherwise specified, be capable of exerting a constant pressure of at least
20bar or as may be required for high pressure grouting. The pump shall be fitted with a currently calibrated pressure gauge with a dial of a suitable
diameter enabling accurate readings to the nearest bar and a valve which can be locked-off without pressure loss. The hoses used shall be
appropriately rated for the pressures required.
d) Tensioning/pre-stressing system
All tensioning systems will be subject to approval by the Engineer. At least 4 weeks before commencing with tensioning operations, the Contractor
shall submit further and full details regarding the stressing system(s), materials, equipment and methods to be adopted in the tensioning and
related operations for approval by the Engineer. The information shall include detailed drawings, proof of successful previous use, performance
certificates from an approved independent testing authority, and calculations substantiating the adequacy of the system.
The system shall comply with BS EN 13391. The Contractor’s proposed system shall comply with the following:
- The tensioning equipment shall be driven by hydraulic power pack, capable of gradual application of a controlled equally distributed and
aligned force to each tendon and anchorage,
- The pressure monitoring unit shall comprise three glycerine damped calibrated gauges complying with BS 1780 (1985), have dials at least
150 mm in diameter and be used within the range of 50 – 90 % of their full capacity at maximum service pressure. The unit’s gauges shall
measure the tensioning force to an accuracy of ±2 %,
- The hydraulic circuits shall have self-sealing connections, and all gauges and hydraulic jacks shall be calibrated immediately prior to use on
site, by an approved, competent authority, and recalibrated as required by the Engineer during the course of the project.
The Engineer may at his discretion approve the use of suitable digital pressure gauges calibrated as specified above. At least two gauges shall
be used. Such approval may be withdrawn if in the opinion of the Engineer the performance is not satisfactory.
A12.2.6.2 Construction equipment for tipping anchors

Equipment necessary for the driving of tipping anchors shall vary according to the anchor size, application, earth characteristics, and objective of
a particular project as indicated in the Contract Documentation. Driving mechanisms may include handheld or machine-mounted equipment.
A12.2.6.3 Construction equipment for screw earth anchors

Equipment necessary for the installation of screw earth anchors shall be appropriate for the anchor size, application, soil characteristics, and
objective as indicated in the Contract Documentation. Driving mechanisms may include handheld or machine-mounted equipment.

A12.2.7.1 General
Permanent lateral support shall be provided as per the Contract Documentation and as detailed in the construction drawings.
A12.2.7.2 Cable anchors

a) Test anchors
Test anchors shall be installed by the Contractor as indicated in the Contract Documentation. The positions shall be agreed with the Engineer on
site. The Contractor shall provide the Engineer with a method statement for the installation of the test anchors covering all aspects of the installation
including the drilling of the holes anchor materials, fabrication, installation, grouting, tensioning and protection as detailed in these specifications
at least two weeks prior to the commencement of the test anchor installation. The test anchors shall be constructed utilising the same methodology,
equipment, materials and workmanship as contemplated for the working anchors. Test anchors shall be proof loaded and stressed in accordance
with the provisions given in Clause A12.2.7.2f). In the case of a test anchor being defective, the Contractor shall re-design and install a further set
of test anchors.
The installation of working anchors will only be permitted on the successful completion and testing of the test anchors. The Contractor shall revise
his method statement as may be necessary following the test anchor installation and submit the revised method statement to the Engineer for his
approval. The Installation of working anchors shall only commence once the Engineer’s written approval has been obtained. Payment will only be
made for successful anchors as instructed by the Engineer.
b) Drilling
(i) General
Holes shall be drilled to the diameter, depth, position and tolerances specified. The length of hole drilled shall be 300 mm greater than
anchor length.
The drilling rig assembly shall be sufficiently rigid and the working platform stable and durable to ensure the specified directional alignment
is achieved.
(ii) Drilling methods
The drilling methods may either be auger, rotary, percussive, rotary-percussive or vibratory and shall be chosen to optimally penetrate
the substrata and achieve minimal disturbance of surrounding ground.
The use and selection of any method shall be entirely at the Contractor’s risk. If the selected method does not produce satisfactory
results, alternative methods shall be used to achieve the required result at no additional cost or extension of time.
If in the opinion of the Engineer the required results are not obtained, or the Contractor’s work method is adversely affecting the in-
situ ground conditions, he will have the right to stop the works. The onus is on the Contractor to propose corrective measures and
present these to the Engineer for approval. No standing time or extension of time will apply during such stoppages.
The use of casing in the free length is permitted, unless otherwise specified in the Contract Documentation.
Where casing is specified or used by the Contractor over the free length to stabilise the holes, the individual casing lengths shall be
welded using a jig designed to ensure that the line remains true and the welds are not severed during installation. The diameter of

such casing should provide for the specified cover over the anchor sheathing to be achieved. The casing shall be trimmed to ensure
that it remains clear of the stressing head throughout the stressing cycles.
The use of drilling fluid is subject to the following conditions:
It shall not cause swelling or softening of the ground.
It shall have no deleterious effect on the ground, tendon or grout.
Special care shall be taken when drilling into ground water with artesian pressure. In such circumstances the Contractor shall propose
an appropriate drilling method to the Engineer for approval.
Should the Contractor encounter ground conditions that differ from those on which the design is based, drilling shall be discontinued,
and the Engineer shall immediately be notified. The Contractor shall propose appropriate measures for approval by the Engineer to
progress the works.
(iii) Tolerances
The holes shall comply with the following:
Minimum hole diameter anchor assemblage plus 10 mm
Inclination at collar of hole ±2,5 of specified inclination
Position of collar at hole ±75 mm of specified position
Length from collar of hole specified length +0,3 m
(iv) Water testing

On completion of drilling the fixed length in rock the drilled hole shall be tested for water tightness. If the loss of water over a period
of 10 minutes exceeds 3 l/min at a pressure of 100kPa at collar level the hole shall be grouted and re-drilled. The water proofing grout
shall be cement grout of similar composition to the anchor grouting. The Contractor shall provide the necessary equipment for carrying
out the testing inclusive of all packers, manifolds and other equipment required to carry out these tests.
The re-drilling shall not commence for at least twelve hours after the waterproof grouting has been completed.
(v) Loss of hole
Where a hole is lost or has to be abandoned due to mechanical breakdowns or failures or any other causes arising from the
Contractor’s activities or failure to protect the works, a new hole shall be drilled, entirely at the Contractor’s cost.
c) Manufacture
(i) Storage, handling and protection
During storage, transit, construction and after installation the sheaths, tendons and anchorages shall be protected against damage or
permanent deformation. The materials shall be stored in weatherproof sheds. All materials shall be stored clear of the ground and
while in storage shall not be exposed to the weather.
When the tendons are stored for a prolonged period and there is evidence of deterioration, the Contractor may be called on to prove
by tests that the quality of the steel is not impaired and complies with the provisions of these specifications. All damaged materials
shall be replaced at the Contractor’s cost.
(ii) Fabrication
The tendons shall be assembled on site under the supervision of approved key personnel. In addition to the Contractor’s process
control, the Engineer reserves the right to carry out inspections of all components and assembled anchors. All completed assemblies
shall be numbered. Records of the process control shall be kept by the Contractor and submitted to the Engineer before installation.
Anchors shall be assembled above ground on suitable trestles or stands. Cutting of strand shall be via high-speed abrasive cutting
wheels. Flame-cutting is not permitted.
The Contractor shall allow a minimum working length of 1,0 m in excess of specified free length plus fixed length. Strands and
anchorages shall be prevented from coming into contact with splashes from flame-cutting or welding processes in the vicinity.
In removing the sheathing, care shall be taken to avoid damage to the strands. Damaged strands shall be rejected. The grease shall
be completely removed from the fixed length of each strand using a suitable solvent. The wires shall be unwound during this operation.
The approved centralisers shall be placed at intervals no greater than 1,5 m centre to centre firmly affixed to the individual strands
and internal fixed length grout pipes. The distal end shall be fitted with a securely attached approved cap or centraliser to prevent
either splaying or congregation of strands. The Engineer‘s acceptance shall be obtained before any assembled tendon is inserted into
the corrugated sheathing. The corrugated sheathing shall be fitted with a water/grout-proof end cap securely affixed/fastened to the
bottom of the corrugated sheathing and able to withstand the rigours of tendon-insertion, homing and grouting. The prepared tendon
or cable shall be labelled to show the tendon or cable number.
The homing grout tubes shall be wound in a spiral around the corrugated sheathing at a pitch less than 1,5 m to provide cover greater
than 10 mm to the outside of the tubes. Where the homing grout tube is located internally and not helically wound around the
corrugated sheath, centralisers shall be placed at intervals less than 1,5 m along the corrugated sheath to provide cover greater than
10 mm.
If specified in the Contract Documentation, high pressure tubes shall be attached in a spiral around the corrugated sheathing at a
pitch less than 1,5 m to provide cover greater than 10 mm to the outside of the tubes. High pressure grouting tubes shall be of the
tube-a-manchette (TAM) type, provided with holes (greater and/or equal to 6,0 mm ϕ) and sheaths (manchettes) at a spacing less
than 750 mm over the fixed length of the anchor. All grout injection tubes shall be colour coded to ensure their correct utilisation.
The assembled anchor shall be stored on trestles or stands and be protected against the ingress of water and other foreign objects.
After fabrication, the cable ends shall be covered with protective wrapping.

d) Homing and grouting
(i) General
Unless otherwise indicated in the Contract Documentation the tendon installation / homing of an anchor and grouting shall be carried
out within 2-4 days after the drilling of the fixed anchor length.
Generally, the anchor shall be homed into a water-filled hole and grout tremmied from the bottom of the hole to completely encase
the anchor. Where indicated in the Contract Documentation the anchor shall be homed in a partially filled tremie grouted hole. Primary
grout operations follow.
The homing shall be carried out at a steady controlled rate. Should any obstructions be encountered during this process or the full
depth not be attained, the cable shall be removed, and the problem rectified by appropriate means.
Sampling and testing of anchorage grout will be required as specified in Clause A12.2.8.1a).
(ii) Homing and encapsulating grouting
Borehole or homing grouting is the tremie grouting of the annulus between the corrugated sheathing and the sides of the hole or
casing.
Encapsulation grouting is the encapsulation of the anchor within the corrugated sheath. Encapsulation grouting may be done prior to
homing or after homing dependant on the type of anchor.
Prior to commencing with the homing- and encapsulation grouting the anchor assembly shall be centred by suitable means to ensure
that the strands remain parallel to the centre of the anchor and perpendicular to the thrust plated when grouted.
The grout shall be injected at the distal end of the hole, through the appropriate grout tubes. These shall be clearly demarcated, or
colour coded.
Grout injection shall be continuous. Injection shall continue until the grout flowing from the hole (homing grout) or from the corrugated
sheath (encapsulation grouting) is of the same consistency as that of the injected grout. The grout levels shall be topped up after
grouting to ensure that the required levels are achieved in the process. Unless a retarder is used in the grout mix, the grout not used
within 60 minutes of mixing shall be discarded.
The fixed anchorage shall be encapsulated in the corrugated sheathing through the primary grout tube. This encapsulation, if done
by pre-injection prior to homing of the anchor, shall be performed in such a manner that no pockets of air or water will remain in the
apexes of the corrugations, and the Contractor shall demonstrate his ability to achieve this to the Engineer whilst installing the trial/site
suitability anchors prior to the adoption of this method for the working anchors.
If the encapsulation is done concurrently with the homing of the anchors, and there is the risk of pockets of air or water being entrapped
in the apexes of the corrugations, the cover over the strand shall be increased to accommodate this. Under these circumstances, it
will be the responsibility of the Contractor to submit the proposed method statement for achieving this to the Engineer.
If delays are encountered in commencement of the grouting process after homing, the anchor shall be removed, and the process
recommenced when the causes have been addressed.
If a blockage occurs during the course of grouting the anchor shall be withdrawn from the hole and removed from the corrugated
sheathing and thoroughly cleaned. Re-assembly shall be done as specified. The hole shall be flushed / re-drilled as directed by the
Engineer.
If in the course of grouting the grout take is in excess of three times the calculated theoretical volume, grouting shall be terminated,
the anchor removed and cleaned as specified. The hole shall then be re-drilled.
Grouting shall not be carried out during very cold weather when the ambient air temperature drops below 5C.
(iii) High pressure grouting
If deemed necessary or specified, high pressure grouting of the fixed length shall be achieved by the injection of grout under high
pressure after the homing and primary grout attains a cube strength greater than 10 MPa.
Water shall initially be used to open the manchettes and to break open the homing grout body. Thereafter, grout shall be used. The
grout shall be injected at a sufficiently high pressure to pass the tube-a-manchettes and penetrate or exert high radial stresses on the
surrounding material to penetrate and/or create extra volume facilitating bonding with the surrounding material and/or creation of a
bulbous anchorage.
Multiple injections may be required. The pressures and volumes of grout per injection will be dependent on ground conditions and
class of tube used. After each re-injection the system shall be thoroughly flushed and further high-pressure grouting carried out until
the grout injection rate less than 1 l/min at the injection pressure. Once the re-injections prove compliance and the grout attained the
specified strength, tensioning may proceed.
Full details of grouting stages performed on the ground anchor shall be recorded on approved forms and submitted to the Engineer
as the work proceeds.
e) Thrust plate seating
The thrust plate shall be seated on a thin mortar bedding of approved materials to bear evenly on the concrete bearing pad, and the tendon axis
shall be perpendicular to the bearing surface of the anchorage.
f) Tensioning
(i) General
Tensioning and testing of anchors as well as the recording shall be carried out by approved, appropriately qualified and experienced
personnel. Tensioning shall only commence once the high pressure grout attains a cube strength equal to or greater than 25 MPa
and the Engineer has given approval for the work to commence. The sequence of the anchors to be tensioned shall be as instructed
by the Engineer.
All instrumentation shall be protected from the elements during tensioning.

Prior to applying any load, the anchor head assembly shall be positioned so that the strands are centrally located within the hole
through the thrust plate and that none snag against it. Wedges shall be oil-free and clean to prevent slippage from occurring and to
allow movement between the wedge and the anchor. Wedges shall be simultaneously knocked tightly in place ensuring uniform grip.
Tensioning shall commence with the uppermost strand, by applying a small load (5-10 % of the final value) to each one to take up
slack and prevent entanglement. This will allow the zero position for measuring the extension to be determined, gripping devices,
position and alignment of the jacks, to be checked. Jacks shall be kept flush with the thrust plate when load is applied utilising hoisting
mechanisms if necessary. The load shall be gradually increased to the full specified tensioning force with intermediate load and
extensions recorded at specified increments. Wedge draw in and possible strand slippage shall be closely monitored.
For recording of tendon/cable extension, a dial gauge or electronic vernier calliper, attached to a free-standing tripod or similar
approved mechanism, shall be used. The instrument shall have an accuracy of 0,01 mm or better.
Prior to tensioning and to detect any slippage, protruding strands shall be marked and cut equidistant from the anchor head such that
more than 700 mm protrudes from the wedge. Cognisance shall also be taken of the projected extension and equipment dimensions.
Tensioning by single-strand jack is permissible, provided the sequential load increment between successive strands is less than 0.1
Tw.
The free length of a tendon may, in certain conditions be such that the extension under load is greater than can be accommodated
by the tensioning jack over the specified range. Single-strand tensioning of the anchor up to 0.5 Tw (the design working load) is
permissible. Full details of the Contractor’s proposals shall be given in the method statements for the tensioning and testing of the
anchors and the Engineer’s approval shall be obtained before commencement therewith.
At tensioning, the following data shall be recorded:
- Date and time started and completed
- Names of personnel responsible for tensioning
- Ground anchor number
- Free and fixed length of anchor
- Tendon type and E-value of steel
- Design, working load (Tw), proof load (1.5 Tw or 1.25 Tw) and lock-off load (1.1 Tw)
- Date of last calibration of gauges and accuracy of gauges
- Type of jack used and ram area of jack
- Tendon extensions during the course of loading and release
- Pressure gauge readings at each load increment
- Ground type
(ii) Testing
Testing of anchors comprise lift-off tests to establish loads on the anchor and to determine the efficacy of installation, by comparing
measured load/extension data with theoretical values. This enables actual free length of the anchor to be determined. Lift-off tests
shall be carried out at 1 day, at 3 days and, in addition for test anchors, at 10 days after initial stressing.
The Contractor shall provide necessary plant, equipment, instruments, calibration certificates and labour to carry out the tests and
monitoring operations to the Engineer’s requirements. All the equipment shall be in good working order. The Contractor shall provide
the Engineer with a programme indicating dates of tensioning and/or testing of all anchors.
Within two days of completing a test, the Contractor shall supply the Engineer with load extension curves, neatly plotted, as well as
tensioning records in accordance with requirements.
(iii) Permissible loads in tendons
No tendon shall at any stage during a test be tensioned beyond 80 % of the characteristic strength.
(iv) Tensioning and testing process
Tensioning and testing of anchors shall be carried out as follows (Tw is the design working load):
1. Tension the anchor and record and plot load/extension data continuously over the range 0.25 to 1.50 Tw in increments of less
than 0.25 Tw. Temporary anchors shall be loaded to 1.25 Tw.
2. The extensions shall be measured relative to a fixed datum independent of the concrete work or surface against which the anchor
is stressed.
3. Each load increment shall be held for a minimum period of 1 minute with the exception of the proof load of 1.50 Tw which shall
be held for 15 minutes.
4. Evaluate additional extension over the 15 minute period in 1. above. This additional extension should be less than 5 % of the
total elastic extension at 1.50 Tw.
5. De-tension the anchor to 0.25 Tw in three equal decrements and record and plot the load/extension values for each step.
6. Calculate the apparent free length of the anchor from the load/extension curve using the manufacturer’s load/extension curves
allowing for the effects of bedding-in of anchor head and any other extraneous factors. The analysis should be carried out over
the range 0.25 Tw to 1.50 Tw. The apparent anchor free length shall be greater than 90 % of the designed free length nor more
than the intended free length plus 50 % of the designed fixed anchorage length. If the apparent free length does not comply with
these limits, the anchor shall be regarded as defective.
7. Repeat the first cycle of loading and unloading and record results as described in points 1 to 3 above.
8. On completion of the second load cycle, reload in one operation and lock off at 1.10Tw utilising selected shims.

Carry out a lift-off test immediately after lock-off to establish initial residual load. If below 1.10 Tw, insert additional shims to
increase the anchor load to 1.10Tw.
9. Lift-off tests should be carried out at 1 and 3 days (and 10 days for test anchors) after initial tensioning. Zero-time is the point at
which the lift-off test, immediately after initial tensioning, reflects a residual load in the anchor of 1.10 Tw. The loss of tension in
the anchor shall be less than 0.06 Tw at 1 day, less than 0.07 Tw at 3 days and less than 0.08 Tw at 10 days.
If during any of these lift-off tests the loss of tension exceeds the amounts specified above, the anchor shall again be tensioned as
described in points 1 to 8 above and locked off at 1.10 Tw. The lift-off tests shall then be repeated at 1, 3 and 10 days as previously
described, after relocking the anchor at 1.10 Tw.
If after such re-tensioning to 1.10 Tw, a test anchor fails to comply with the maximum permissible losses in tension indicated above,
the anchor shall be regarded as defective. This anchor shall be condemned or de-rated or otherwise dealt with as directed by the
Engineer. If the losses in tension do not exceed the percentages specified above at 1 and 3 days (and 10 days for test anchors) the
anchors shall be considered acceptable.
After stressing, a check should be carried out to ensure that all of the cables are properly tensioned. This includes checking for the
following:
- Broken wires which lead to other wires slipping past the broken wire as tensioning continues, leaving the end of the broken wire
protruding beyond the ends of the other wires;
- Wedges inadequately seated as evidenced by non-uniform embedment; and
- Wedges not adequately gripping strands, evidenced by disparate lengths of strands.
- Any deficiencies shall immediately be brought to the Engineer’s attention.
g) Routine acceptance tests for working anchors
Each working anchor shall be subjected to routine acceptance testing and checking of the free length as described in points 1 to 10
above. The 10-day lift-off test shall, however, not be required. Provided the apparent free length complies with (d), the anchor shall be deemed to
be acceptable if at 24 hours after lock-off, the loss of load does not exceed 6 % Tw and at 3 days after lock-off the loss of load does not exceed
7 % Tw. If at the 24-hour lift-off test or at the 3-day lift-off test the loss of prestress exceeds the allowable (6 %, 7 % Tw respectively), the anchor
shall again be locked off at 110 % and subjected to further tests at 24 hours and 3 days. If after either the second 24 hour or 3 day re-test, the
loss of prestress is still greater than the allowable, the anchor shall be regarded as a defective anchor and the anchors shall be condemned or
de-rated or otherwise dealt with as directed by the Engineer.
h) Protection
After the tensioning and testing have been completed and approved, the anchorages at the jacking end shall be filled with grease with particular
attention being paid to the annulus behind the anchor head. This shall be completely filled with the approved grease employing a suitable pump,
injecting the grease under pressure until it exudes between the wires of the individual strands. The anchor head shall then be thoroughly coated
with the grease before fitting and securing the partially grease filled permanent cover. Grease shall then be pumped through the lower grease
nipple until it exudes from the upper grease nipple hole.
The permanent covers shall then be cleaned and monitored for any loss of grease, externally or internally over the defects notification period.
Defective seals or gaskets shall be replaced and the covers refilled with grease all at the Contractor’s cost.
All anchor components shall be protected against damage or corrosion and shall be stored under cover until assembled / installation. Assembled
anchors shall be stored on trestles or similar approved installations and protected against ingress of water or other materials
All drilled holes shall be suitably sealed to prevent the ingress of water and foreign objects. Should the measures taken by the Contractor fail in
this regard the Engineer shall instruct the Contractor as to what measures shall be carried out to redress the situation. Holes lost due to the
Contractor’s negligence shall be re-drilled at his own cost. All other extra costs incurred thereby will be to the Contractor’s cost.
Installed but not yet tensioned anchors or not yet treated with rust inhibiting grease and permanent grease caps shall be suitably protected from
dust, water and other contaminants to the satisfaction of the Engineer. The works shall also be protected against vandalism by outsiders until all
the works have been completed and handed over.
A12.2.7.3 Soil nails, rockbolts

a) General
Soil nailing shall be further undertaken with special reference to BS EN 14490:2010.
Rockbolts or soil nails or mechanical earth anchors of varying length shall be placed at orientations on the excavation face or on other locations
to provide support requirements. Spacing may be random; patterned or inserted as spot bolts / nails. Bolt / nail length; spacing; diameter; strength
and protection against corrosion shall be as specified. The Engineer shall be accorded access to the bolting/ nailing position; to assess the stability
of the cut face or natural slope. The Engineer shall indicate the number, sequence, precise location, length and orientation of bolts required, and
may increase or decrease the number as necessary.
Soil nails or rock bolts shall be installed immediately as part of the excavation cycle at intervals specified by the Engineer to ensure its stability
and to limit defamations as the excavations advances and be complete and approved before the ensuing excavation advance may commence,
unless otherwise instructed by the Engineer in writing.
b) Trials
The Contractor shall provide the Engineer with a method statement for the installation of test soil nails/ rockbolts. The Contractor shall carry out
comprehensive trials to the satisfaction of the Engineer at least four weeks prior to the commencement of any permanent rock bolting / soil nailing.
Rock bolt / soil nail pull out tests will also be undertaken on the test bolts/nails in accordance with specifications. Changes as necessitated by the
outcomes of these tests, shall be made to the method statement which shall be submitted to the Engineer for approval four weeks before being
allowed to proceed with production work. Trials which are unsuccessful and/or which in the opinion of the Engineer do not meet the requirements
of the specification will not be measured or paid for.

c) Inspection by the Engineer
The Contractor shall provide suitable plant, equipment and training, together with a competent operator to ensure safe and appropriate access for
the Engineer right up to any part of the site requiring stabilisation to undertake whatever, observations, measurements or samples that may be
required. No work which could pose a hazard to or disrupt these specialist inspections shall be undertaken by the Contractor on or near the area
under inspection for the full duration of the inspection.
Notwithstanding the Contractor’s previous finishing efforts, the Engineer will determine the final positions of rock bolts or soil nails required as well
identify all blocks or wedges of rock or boulders or any other protuberances which require removal or stabilisation. The Engineer will confirm the
final number, location, length, and orientation of each rock bolt / soil nail within two working days of inspecting a works zone.
d) Drilling
(i) General
The drilling methods for the installation of nails or bolts may either be by rotary, percussive, rotary-percussive, augering or vibratory
methods, with or without using temporary casing and shall be chosen to ensure the minimum possible disturbance to the surrounding
ground and a stable hole which will facilitate the insertion and grouting of the soil nails or rock bolts to the required tolerances and
specification. Unless otherwise specified or instructed by the Engineer, the selection of method shall be entirely at the Contractor’s
risk. Should the selected method result in unstable holes or prevent efficient execution of work which does not meet the requirements
of these specifications, the Engineer may instruct the Contractor to stop work and the Contractor shall adopt alternative drilling
methods. No additional payment shall be made in this regard other than provided in the pricing schedule. No standing time or
extensions of time shall be granted.
The use of drilling fluid shall not adversely affect ground conditions. Special care shall be taken when drilling into artesian ground
water.
Work must immediately stop should conditions other than indicated in the Contract Documentation be encountered and the Engineer
informed. Works shall only proceed on instruction of the Engineer.
(ii) Drilling requirements
Holes for rock bolts / soil nails shall be drilled to a diameter at least 25 mm greater than the nominal diameter of the bolt/ nail.
To avoid excessive deviation particular care is required when advancing the hole. The following tolerances are applicable:
- Diameter of hole: + 10 mm and – 5,0 mm,
- Position of hole: less than 75 mm from specified position,
- Alignment: less than 2,5 % of specified inclination,
- 50mm less than length of drill hole less than 250 mm of required hole length.
After each hole is drilled to its full length and flushed via compressed air and/or water to remove all loose materials, it shall be probed
to ensure collapse has not occurred and that it is clean over its full length. Thereafter the hole shall immediately be plugged to prevent
debris from entering.
Where a hole is lost or abandoned due to mechanical breakdowns, failures or any other causes arising from the Contractor’s omission
to protect the works, a new hole shall be drilled, entirely at the Contractor’s cost.
e) Bolt / nail insertion
The bolts are to be fitted with centralisers or a spirally wound grout tube providing the specified cover less than 1,5 m spacing/pitch, homed and
grouted to the collar as specified. A minimum of two centralisers are required for bolts less than 2,0 m, with a centraliser 300 mm from the proximal
and distal ends. The bolt must protrude or be trimmed sufficiently for the application envisaged.
Mechanically end-anchored expansion shell rockbolts shall comprise a screwed end tapered cone with an internal thread and a pair of wedges
secured by a bail. The full assemblage is inserted into a pre-drilled hole, 100 mm longer than the bolt, to ensure the bail is not dislodged when
forced against the end of the pre-drilled hole.
Split-set bolts are inserted into pre-drilled holes of diameter less than bolt Ø to ensure frictional anchorage along its entire length via the radial
force generated through compression of the C-shaped tube.
Swellex dowels, folded during manufacture, are activated after insertion into a predrilled hole, by injection of high pressure (greater than 30MPa)
water discharge.
Corrosion-resistant coatings are mandatory for both split-set and proprietary expandable folded tube rockbolts and dowels.
f) Grouting
All rock bolts / soil nails shall be grouted to the collar of the hole, either by way of cement grout with or without additives or using cement or resin
cartridges as approved by the Engineer. The Contractor shall ensure that whatever method is used, the grout cover to the bolts / nails is continuous
and completely fills the annulus between the bolts and rock or soil. Special precaution is required to inhibit bleed and shrinkage of cement grouts.
All cartridge grouts must be sufficiently mixed to ensure required homogeneity.
If for any reason, grouting is interrupted and/or the installation of the bolts is delayed, the bolt shall be removed timeously from the hole before
hardening. The grout shall then be removed by flushing or re-drilling and the bolt re-installed.
Grout shall be injected at the distal end of the hole, through appropriate tubes. Injection shall be continuous until flow occurs from the collar.
g) Rockbolt head protection and camouflage
After rock bolts / soil nails are installed successfully, grouted, tensioned where required, and approved by the Engineer, the bolt head shall be
trimmed as specified. The exposed face plate and protruding end of the bolt shall be camouflaged to blend with the surrounding area and protected
via a suitably pigmented patch of shotcrete, or hand-packed mortar with minimum of 150 mm greater than plate dimensions and cover greater
than 50 mm or by a corrosion-inhibiting suitably-pigmented paint, equipped with an Engineer-specified (non-spot welded) suitable anti-theft
mechanism.
h) Tensioning
Tensioning of rock bolts shall be carried out by experienced personnel. Tensioning to less than 0.57Tult shall be either by manual or pneumatic
torque wrench or jacks as specified.

A12.2.7.4 Mechanical Driven Tipping Anchors (MDTA)
a) General
Mechanical driven tipping anchors (MDTA’s) shall be driven into the soil using hand held hammers or appropriate mechanised methods, depending
on anchor capacity and soil condition. Once inserted to design depth, the anchor shall be tipped and tensioned to attain its working load. Smaller
anchors are hand-tensioned but larger anchors require load locking to both seat the anchor tip and ensure tensioning to the design load. In all
cases care shall be taken not to remove the drive steel from the anchor during the adding of coupled extensions, drive steel and steel anchor
rods, since this may cause the anchor to rotate into its locked position and possibly inhibit further advance and circumvent later removal of the
anchor to a new position.
b) Installation
Pre-drilled holes are required for installation in dense to very dense soils or highly/completely weathered rock. Weathered rock requires a larger
pre-drilled hole than dense soils since the anchor tends to slide in harder incompressible rock material.
Removal of the drive steel shall generally be accomplished by hand, hammer vibration or use of a load locker .
A12.2.7.5 Mechanical screw anchors

Screw anchors shall be rotated into the soil using manual methods or by mechanical shaft rotation equipment for higher capacity applications.
Length and depth of installation shall be specified and tested as required by the Engineer following field trials.
A12.2.8 WORKMANSHIP
A12.2.8.1 Cable anchors
a) Cementitious grout
Immediately after mixing, and also during injection, the fluidity of the grout shall be tested at regular intervals in accordance with Clause
A20.1.5.6b)(iv) of Chapter 20. Viscosity tests may also be specified in the Contract Documentation.
During the course of grouting, 100 mm cubes shall be made, cured and tested in accordance with SANS 3001-CO11.
Six cubes per batch of anchorage grout shall be made, of which two shall be tested at 3 days, two at 7 days and two at 28 days. The testing shall
be carried out by an approved, SANAS accredited laboratory facility in terms of their accredited tests. The compressive strength of 100 mm cubes
made of the grout and cured in a moist atmosphere for the first 24 hours and thereafter in water at 20°C shall exceed 30 MPa at 7 days and 40
MPa at 28 days. The test results shall be reported within two days of the test date.
The fluidity and consistency of each grout batch mixed shall also be measured with a flow cone and, if specified, with a viscometer in accordance
with Clause A20.1.5.6b)(iv) of Chapter 20.
Grouting shall only be undertaken when the ambient air temperature is greater than 5C.
b) Concrete
All concrete for structural work associated with ground anchors and which is not covered elsewhere in the project documents shall comply with
the provisions of relevant Clauses of Chapter 13.
The Contractor shall bear the cost of all acceptance tests specified in the contract or prescribed by the Engineer and which are not listed in the
pricing schedule.
The results of tests on concrete shall be assessed according to Clause A20.1.7.5b) (ii) (Judgement Plan B) of Chapter 20.
c) Records
(i) Daily records
Daily records shall be kept in respect of each of the following phases of anchor construction:
- Drilling
- Anchor installation
- Anchor tensioning
(ii) Project records
• The project records to be prepared by the Contractor and submitted to the Engineer on completion of the anchoring shall include,
as a minimum, the following:
• Project details
• Anchoring details (numbers, positions, types, orientation, protection)
• per anchor, the following (as applicable):
o Anchor Number Anchor details (type, free length, fixed length, no of strands, design load)
o Date drilled
o Date installed
o Date grouted
o High pressure grouting details (dates, pressures, grout takes)
o Date tensioned, working load (Tw), proof load (1.5 Tw or 1.25 Tw) and lock-off load (1.1 Tw)
o Grout Test Data

The format shall be approved by the Engineer.
A12.2.8.2 Rockbolts, soil nails

a) Tests on cement grouts----as for cable anchors
The provisions in Clause A12.2.8.1a) for Cable Anchors shall apply where cement grouts are to be utilised.
The fluidity of the grout shall at all times be measured with a CSRA flow cone or similar approved and calibrated as specified.
b) Rock bolts / soil nails
The Contractor shall carry out process control testing to demonstrate that the rock bolts / soil nails are able to withstand the specified working
loads. For this purpose the Contractor shall provide connectors to the protruding rock bolts / soil nails in order to execute this work. 10 % of bolts
/ nails, up to a maximum of 30, shall be tested. If excessive percentages of failure occur the number of bolts to be tested may be increased at the
discretion of the Engineer.
The bolts/ nails shall be tested in accordance with prEN 22477-6, Methods A and B. Testing shall only be done until the grout and/or shotcrete
facing have cured for at least 72 hours and have obtained the specified 3-day compressive strength.
The rock bolts / soil nails shall be tested to 115 % of the required working load no sooner than 3 (three) days after grouting has been completed.
The tests will be undertaken with a suitably light hydraulic jack fitted with three pressure gauges which can be read to an accuracy of 1kN.
Deflections of the bolt head are to be measured with a dial gauge to an accuracy of 0,1 mm. The jack and dial gauge will be required to be
calibrated by an accredited laboratory approved by the Engineer at the commencement of the project, and whenever this may be required again.
The certificate of calibration must be submitted to the Engineer for his approval. All rock bolt pull out tests shall be undertaken in the presence
and to the requirements of Engineer.
Should a rock bolt fail a test, the Engineer will instruct the Contractor to either remove; re-drill, and install the defective bolt, or if this is not possible,
to re-drill and install a new bolt at the position and orientation directed by the Engineer. This additional work will be undertaken at the Contractor’s
cost. Payment for bolts which have been measured and subsequently found to be defective will be subtracted from the following payment
certificate. The bolt will be tested again once it has been re-installed or replaced. Once the Contractor has demonstrated that the bolt can
withstand 115 % of the required working load it will be re-measured for payment.
In the case of mechanical driven tipping anchors and mechanical screw earth anchors, the products are very varied. Quality and workmanship
shall be controlled as per the manufacturer’s design and installation specifications or to specification as instructed by the Engineer in the Contract
Documentation
The cost of all such tests shall form part of the Contractor’s normal process control and shall be deemed to be included in the tendered rates and
shall not be paid for separately.
c) Records
During the drilling operations, all changes in penetration rate and changes in ground type shall be recorded together with notes on water levels
encountered, drilling rates, flushing losses or gains, and stoppages. The Contractor shall, notwithstanding the above, notify the Engineer
immediately of any ground conditions contrary to that recorded on the drawings are encountered. The Contractor shall further record the date
and times during which each hole is drilled and the subsequent date on which the bolts are grouted and installed. Before work commences the
Contractor shall submit a suitable pro forma of the proposed daily record. Once approved by the Engineer, the Contractor shall submit these
records to the resident Engineer on a daily basis for approval and measurement purposes.
A12.2.8.3 Performance monitoring

a) Cable anchors
(i) Long term monitoring
Monitoring to determine creep and other losses for permanent anchors shall be carried out by means of lift-off tests between 9 and
12 months after construction thereof (i.e. within the defects notification period).
If the residual force in the tendon during monitoring is below 0.92Tw, the Engineer will decide whether to proof load again to 1.5Tw
and lock off at 1.1Tw, followed by 24 hour, 3 day and 10 day tests, or whether to conduct further lift-off tests at shorter intervals.
(ii) Defective ground anchors
Anchors unable to retain a load of 0.92Tw shall be considered defective. These ground anchors shall be corrected by one of the
following methods approved by the Engineer:
Abandoning the ground anchor and replacing with a new ground anchor,
Post-grouting and retesting the ground anchor,
Revisiting the design by the Engineer to establish what additional measures may be required to ensure the long-term performance of
the anchored structure.
If the loss of tension is attributable to deficiencies in the Contractor’s work, the above remedies shall be at his cost.
Where additional works are instructed by the Engineer that is not due to Contractor deficiencies, these shall be paid at tendered rates,
except for the re-establishment which shall be paid for separately.

B12.2 GROUND ANCHORS
CONTENTS
B12.2.1 SCOPE
B12.2.2 DEFINITIONS
B12.2.3 GENERAL
B12.2.5 MATERIALS
B12.2.8 WORKMANSHIP
B12.2.1 SCOPE
B12.2.2 DEFINITIONS
B12.2.3 GENERAL

B12.2.5 MATERIALS


B12.2.8 WORKMANSHIP

C12.2 GROUND ANCHORS
(i) Preamble
pay items.
C12.2.1 Establishment on site for anchoring lump sum
The unit of measurement shall be a lump sum.

The tendered lump sum for anchoring shall include full compensation for establishing all necessary plant and equipment on site to carry out the
works, preparing the work area for drilling, grouting and subsequent anchoring, and for removal from site of all such plant and equipment including
all temporary works such as access roads, staging, platforms and such like on completion of the works.
The work shall be paid as a lump sum, 50 % of which shall be due when all equipment is on site, trials (if any) are completed and the first production
anchor is installed to the satisfaction of the Engineer. The second instalment of 25 % shall be payable after half the number of positions are
anchored and the final 25 % instalment after all anchoring is complete, tested, accepted and equipment removed from site.
The tendered lump sum shall include full compensation for all post-construction requirements as specified.
No extra payment shall be made for establishment of additional plant should the established plant not be capable of achieving desired objectives.

C12.2.2 Re-establishment on site for additional work (type indicated) lump sum
The unit of measurement shall be a lump sum.

The tendered lump sum for anchoring shall include full compensation for re-establishing all necessary plant and equipment on site to carry out
additional works as instructed by the Engineer and shall include all aspects detailed in Clause A12.2.8.3a)(ii).
C12.2.3 Provision of access to anchor positions lump sum
The unit of measurement shall be the provision of access to the anchor positions as specified in the Contract Documentation.
The tendered rate shall include for all labour, plant and equipment required to provide access to the anchor positions as specified.
C12.2.4 Moving to, and setting up the equipment for drilling the holes at each position number (No)
The unit of measurement shall be the number of positions to which the drilling equipment has to be moved and set up in position to drill an anchor
hole. The quantity measured shall be the number of set ups at anchor positions as well as at site suitability /trial anchor positions or at positions
where the Engineer has ordered re-drilling of the holes.
The tendered rate shall include full compensation for all costs involved in moving and setting up any equipment.
C12.2.5 Drill holes with a diameter of (diameter indicated) to the specified depths and
metre (m)
inclinations
The unit of measurement shall be the metre of hole, including the depth of the bulbous base formed, as may be applicable. The depth of the
bulbous base shall be deemed to be equal to the diameter of a sphere, the volume of which shall be equal to the quantity of compacted concrete
in the bulbous base.
The tendered rate for forming augered holes shall include full compensation for augering and disposing of surplus material resulting from the hole
having been formed.
The tendered rate for forming bored holes shall include full compensation for boring, supplying, installing and extracting the driven temporary
casing as well as for disposing of surplus material resulting from the hole having been formed.
C12.2.6 Installation of permanent casing (size and length indicated) metre (m)
The unit of measurement shall be the metre of permanent casing installed.

The tendered rate for installing permanent casing shall include full compensation for the supply and installation of permanent steel casings,
complete with casing shoes and ringbits, including all welding, plant, labour and overhead costs in the indicated lengths.
C12.2.7 Water tests number (No)
The unit of measurement shall be the number of holes tested.

The tendered rate shall include full compensation for installing and the subsequent dismantling and removal of the testing equipment, conducting
the test and processing and submitting the results.
C12.2.8 Grouting and re-drilling the holes metre (m)

The unit of measurement shall be the metre of hole grouted and re-drilled.
The tendered rate shall include full compensation for all grouting materials and equipment, the grouting operation, re-setting up drilling equipment, the
re-drilling operation, flushing and cleaning the hole to provide a watertight hole.
C12.2.9 Cable anchor tendons:
meganewton-metre
C12.2.9.1 Free anchor length
(MN-m)
meganewton-metre
C12.2.9.2 Fixed anchor length
(MN-m)
The unit of measurement shall be the meganewton-metre which is calculated as the product of the characteristic strength (in megapascals) of the
prestressing steel, the cross-sectional area of the tendon (in square metres) and the length of the tendon (in metres) between the outer faces of the
anchorages. In the case of fan and loop anchorages the "length of the tendon" shall include the length of tendon forming the loop or fan.

The tendered rates shall include full compensation for preparing and submitting the drawings, supplying, storing, handling and protecting all materials
(excluding anchorages and couplers at the jacking end), fabricating, supporting and installing the cables, lubricating, permanently protecting and
bonding the tendons, for the using of all the equipment, as well as for all work and incidentals required for completing the work as specified.
C12.2.10 Anchorages and couplers:
C12.2.10.1 anchorage at jacking end meganewton (MN)
C12.2.10.2 Coupler at jacking end meganewton (MN)
The unit of measurement shall be the meganewton which is calculated as the product of the characteristic strength in megapascals of the pre-stressing
steel and the cross-sectional area of the tendon in square metres, effectively anchored or coupled.
The tendered rates shall include full compensation for supplying, storing, handling, fabricating and protecting the complete anchorage or coupler
assembly, anchorage reinforcing, constructing the recesses for the anchorage or coupler, tensioning of the tendons, anchoring and/or coupling,
trimming the tendon ends, using all the equipment, as well as for all work and incidentals required for completing the work as specified. It shall also
include full compensation for testing the tendons to the specified test force in accordance with the prescribed methods.
The coupler shall include the complete assembly consisting of the anchorage built into the first-stage construction and the part coupled to it.
C12.2.11 Encasing the anchorages at the jacking end in concrete number (No)
The unit of measurement shall be the number of anchorages encased.

The tendered rate shall include full compensation for all materials, equipment, plant and labour required for protecting the anchorages at the
jacking end with approved grease filled permanent covers as specified and detailed on the drawings.
C12.2.12 Performance monitoring of anchors
C12.2.12.1 Establishment of lift-off testing team and equipment lump sum
C12.2.12.2 Lift-off tests number (No)
The tendered lump sum shall include full compensation for establishment on site and subsequent removal of all the plant, equipment and
incidentals required for monitoring by means of lift – off tests and the re-tensioning of the anchors.
This work will be paid for as a lump sum, of which 75 % will become payable when all equipment is on site and the first anchor has been monitored
and the remaining 25 % will become payable after all anchors have been monitored and re-tensioned where required and the equipment has been
removed from site.
The unit of measurement for the lift-off tests shall be the number of anchors monitored or re-tensioned.
The tendered rate shall include for the supply and installation of all testing equipment, material, incidentals (including transport and
accommodation) as well as competent experienced personnel for the testing of the anchors as specified and for the preparation and submission
of tensioning records. The tendered lump sum shall also include for the removal and replacement of the grease cap, the refilling of the crease cap
with similar approved grease and ensuring a leak proof seal thereto. rockbolts, dowels, soil nails
C12.2.13 Establishment on the site for drilling of rockbolts, dowels, soil nails or mechanical lump sum
anchors (type indicated)
The tendered lump sum shall include full compensation for generally levelling the drilling site to the required post construction levels (where
applicable), establishing on site with and subsequent removal of all structural platforms, rafts and all special plant and equipment for drilling and
for carrying out operations, the cost of which does not vary with the actual amount of drilling done.
No additional payment will be made for the establishment of other or supplementary plant and ancillary equipment should that initially established
by the Contractor be incapable of penetrating the subsurface soil or rock formations, or achieving the desired hole formation without undue
disturbance of the surrounding material, or achieving the required production rate.
This work will be paid by lump sum: 50% payable when all equipment for the works is on site and the first hole has been drilled. The next 25% of
the lump sum will be payable after half the total number of holes have been drilled, and the final 25% after all the holes have been drilled and the
equipment has been removed from the site.
C12.2.14 Move to and set up at each rockbolt, dowel, soil nail or mechanical anchor position number (No)
The unit of measurement shall be the number of set ups as instructed and approved by the Engineer.
number (No)
C12.2.15 Install, grout and protect soil nails or rock bolts (lengths indicated)
The unit of measurement shall be the number of rock bolts / soil nails installed as specified and as approved by the Engineer.

The tendered rate shall include full compensation for drilling, cleaning drill holes, procuring, corrosion protection, installing and seating rock bolts
with all ancillary face plates, washers and nuts, grouting, protection of bolt ends and face plates, testing bolts as required, all labour, materials
and all other incidentals required to complete the work in accordance with the Contract Documentation and the Engineer’s instructions. All pull out
test requirements and costs are deemed to have been included in this payment item and no extra payment will be made in this regard.
C12.2.16 Extra over for tensioning soil nails or rockbolts number (No)
The unit of measurement shall be the number of rock bolts / soil nails tensioned in accordance with the Engineer’s instruction.
The tendered rate shall include full compensation for labour, plant, equipment, materials and all other incidentals required to complete the work in
accordance with the Contract Documentation and as instructed by the Engineer.
C12.2.17 Apply rock bolt protection and camouflage number (No)
The unit of measurement shall be the number of rock bolt heads protected and / or camouflaged as instructed and approved by the Engineer.
The tendered rate shall include full compensation for the supply of all materials and work required to apply the protection and / or camouflage
layer.
C12.2.18 Move to and set up at each mechanical driven tipping anchor/ mechanical screw anchor number (No)
position (type indicated)
The unit of measurement shall be the number of set ups as instructed and approved by the Engineer.
The tendered rate shall include full compensation for access to the work face or position, dismantling, moving, erecting and commissioning all
plant, equipment and instruments required at anchoring location. The rate shall also include for undertaking the specified process control testing
and providing the Engineer with access to the work face. This item shall be paid for only after the entire anchoring operation has been completed
and approved by the Engineer.
C12.2.19 Install mechanically driven tipping anchors / mechanical screw anchors (type and
number (No)
lengths indicated)
The unit of measurement shall be the number of mechanical driven tipping plate soil anchors / installed to depths as instructed and approved by
the Engineer.
The tendered rate shall include full compensation for procurement of materials, corrosion protection, installation, and seating of anchors, load
locking, tensioning to the design working load and testing, as may be applicable. Installation shall include all ancillary face plates, washers and
nuts, protection of anchor ends and face plates, testing anchors as required, all labour, materials and all other incidentals required to complete
the work in accordance with the Contract Documentation and Engineer’s instructions. All pull out test requirements and costs are deemed to have
been included in this payment item and shall not be paid for separately.

D12.2 GROUND ANCHORS
CONTENTS
B12.2.1 SCOPE
B12.2.2 DEFINITIONS
B12.2.3 GENERAL
B12.2.5 MATERIALS
B12.2.8 WORKMANSHIP
D12.2.1 SCOPE
D12.2.2 GENERAL
published instructions

- Materials as per Clause A12.2.5,
- Execution of the Works as per A12.2.7.
Performance specifications shall be provided for the following:

Prestressing system:
a) Proven track record;
b) Compliance with an internationally recognized standard such as EN 13391.








12.3 GROUND IMPROVEMENT
CONTENTS
A12.3.1 SCOPE
A12.3.2 DEFINITIONS
A12.3.3 GENERAL
A12.3.5 MATERIALS
A12.3.8 WORKMANSHIP

A12.3 GROUND IMPROVEMENT

A12.3.1 SCOPE
This Section covers design and ground improvement via Geotechnical Grouting, Jet Grouting, Compaction Grouting, Dynamic Compaction, Rapid
Impact Compaction, Vibration Compaction/Vibroflotation, Underpinning, Preload Monitoring and Basal reinforcement
A12.3.2 DEFINITIONS
Grout - is a cementitious, pumpable material injected into soil or rock, filling voids, stiffening, setting and effectively bonding with adjacent
materials.
Geotechnical Grouting - includes:
- Contact grouting - Contact grouting is the injection of grout under pressure into the interface between man-made structures and soil/rock.
- Fissure Grouting - Fissure grouting is injection of grout under pressure into fissures, joints, fractures and discontinuities, in rock.
- Gravity Grouting - Gravity grouting is grouting carried out with no applied pressure, sometimes referred to as tremie-grouting.
- Permeation Grouting - Permeation grouting is the replacement of interstitial water or air in a porous medium with grout at injection pressures
sufficiently low to prevent displacement.
- Jet Grouting - Jet grouting is a ground improvement technique whereby in situ materials are mixed with cementitious grout by eroding the
in situ material with a high velocity cementitious grout slurry, with or without compressed air/water, through an injection monitor attached to
the drill string to generate a mixture of soil and cement (soilcrete).
Single Jet Grouting - is the jet grouting technique where a single fluid, typically neat cementitious grout, is used.
Double Jet Grouting - is the jet grouting technique where one fluid, typically neat cement grout, is injected at high velocity assisted by air.
Triple Jet Grouting - is the jet grouting technique where one fluid, typically water, is injected at high velocity through horizontal radial nozzle(s)
and is assisted by a second “fluid”, typically air delivered through a coaxial nozzle(s), to erode the in-situ soil, while a separate nozzle placed lower
on the monitor delivers a third fluid, typically neat cement grout, at lower velocity to simultaneously fill the soil zone eroded by the cutting fluids
(air and water).
Jet Grouted Soilcrete Columns - are formed by simultaneously rotating and lifting the monitor at predetermined rates, while injecting cementitious
grout slurry (and air/water) creating a soilcrete mix with the eroded materials to form columns.
Monitor - the monitor transmits jet grouting fluids to the injection point/s, at high velocities. The monitor is attached to the bottom of the drill string.
Jet Grouting Drill String - are multi-conduit drilling rods for the separate conveyance of jet grouting fluid(s) to the monitor and drill bit.
Drill Bit - is an attachment at the bottom of the drill string to form a pilot hole for the required jet grouted column. These may be claw or drag bits
or any other bits that can produce the desired hole without unduly disturbing the surrounding materials.
Soil Return - includes all surplus materials exuded from the cavity/ hole during the jet grouting process and typically includes liquids, soil and soil
cement slurries as well as solids from the in-situ materials.
Grout Hydrometer - is an instrument used to measure the specific gravity (or relative density) of cementitious grouts and drilling fluids.
Drilling Aid - is a material mixed with drilling water to aid the drilling process and particularly the flushing of drill cuttings from the hole. Cement is
typically used.

Mushroom Heads - are widened upper portions of soilcrete columns.
Compaction Grouting - is a high-pressure, stiff mortar grouting technique that displaces and compacts low density soils.
Dynamic Compaction - is a technique whereby low-density in situ soils are improved by repeated dropping a large weight from great height.
Dynamic Replacement - is a technique whereby in situ soft/loose soils are displaced by stone columns driven into the soils by dynamic
compaction.
Rapid Impact Compaction - is a technique whereby in situ soils are compacted by dropping a large weight from a low height at rapid frequency.
Vibro-compaction - is a technique whereby soils are compacted by vibrating immersion probes with or without the addition of stone. Also known
as vibro-flotation or vibration compaction.
Underpinning - is a technique whereby an existing structure is supported post construction.
Preloading - is the controlled early construction of road embankments to facilitate consolidation and construction processes over compressible
substrata.
Preload monitoring - is the monitoring of early construction of road embankments for stability and settlement.
Basal reinforcement - at the base of a fill embankment to either ensure stability of the slope or alternatively to bridge local soft areas or voids.
Geosynthetic Materials - collective term for geogrids, geotextiles and geocells made from a synthetic or natural polymer, in the form of a sheet,
a strip or a three-dimensional structure, used in contact with soil and/or other materials in geotechnical and civil engineering applications
Geogrid – planar, polymeric structure consisting of a regular open network of integrally connected tensile elements which may be linked by
extrusion, bonding or interlacing, whose openings are larger than the constituents,
Geotextile – planar, permeable, polymeric (synthetic or natural) material, which may be woven, non-woven or knitted, used applications used in
contact with soil and/or other materials in geotechnical and civil engineering applications
Geocells - three-dimensional, permeable, polymeric (synthetic or natural) honeycomb or similar cellular structure, made of linked strips of
geosynthetics filled with soils or gravels.
Separation layers - are placed below basal reinforcement to limit penetration into the soft, low quality substrata under the kneading action of
tyres of construction traffic or to prevent intermixing of dissimilar materials. These separation layers generally involve the use of selected
geosynthetics and/or geogrids.
A12.3.3 GENERAL
Due allowance shall therefore be made in his programme. Allowance shall also be made for allow for the Engineer’s assessment of the trials,
procedures followed, and materials and plant utilised and of the test data. Production work shall not be permitted until it is shown and accepted
by the Engineer that the Contractor possesses the necessary experience, plant and equipment to carry out the works as specified in the Contract
Documentation.

Due allowance shall be made for obtaining materials, resubmissions and re-designs, all to the required/approved standards, methods and
practices in attending to these requirements. Particular attention shall be paid to the early submission of materials-, concrete- and grout mix
designs where parameters at various ages may be specified. No consideration for extension of the contract period will be entertained for delays
incurred in meeting these requirements.
of the works:

Table A12.3.3-1: Required Approvals

Grout mix designs for Geotechnical grouting, Jet grouting 6 weeks before programmed use
A12.3.4 in permanent works
and/or Compaction grouting
Materials Approvals (MA)
MA for Geotechnical Grouting, Jet Grouting, Compaction Grouting, 2 weeks before programmed use
Dynamic/Replacement Compaction, Rapid Impact Compaction, in permanent works
A12.3.6
Vibration Compaction/Vibroflotation, Underpinning, Preloading and
Basal reinforcement
Construction Method Statements (CMS)
6 weeks before programmed

CMS for Geotechnical Grouting, Jet Grouting, Compaction Grouting,
construction of permanent works
Dynamic/Replacement Compaction, Rapid Impact Compaction,
A12.3.7 and after the Engineer’s approval
Vibration Compaction/Vibroflotation, Underpinning, Preloading and
of designs and construction
Basal reinforcement
materials
A12.3.3.3 Geotechnical grouting

Geotechnical grouting is the process in which the remote placement of a cementitious, pumpable material in the ground or rock is indirectly
controlled by adjusting its rheological characteristics (constituents, mix proportions, strength, physical properties, etc.) and by the manipulation of
the placement parameters (pressures, volume and flow, rate) all to achieve the requisite Engineering performance.
There two broad methods covered in these specifications are:
- Displacement grouting (jet grouting and compaction grouting)
- Non-displacement grouting (fissure grouting, contact grouting, gravity grouting, permeation grouting, penetration grouting and curtain grouting).
Contact grouting is done to fill the cavities/voids between concrete and rock mass on account of shrinkage of concrete and uneven over
breaks. Consolidation grouting is done to strengthen the surrounding rock mass by filling up the open joints, fissures, cracks etc. Curtain grouting
involves the construction of a narrow excavation and filling it with concrete or by the creation of a thin grout curtain by pressure grouting holes at
closely spaced intervals, each grout pillar intersecting the adjacent grout pillar.
A12.3.3.4 Jet grouting

Jet grouting is the process whereby in situ materials are eroded by high velocity grouts and mixed therewith to form soilcrete columns. These
specifications cover the construction of soilcrete columns for ground improvement purposes to meet the project objectives described in the
Contract Documentation. The works are of a highly specialised nature and shall only be carried out by Contractors who have the necessary
experience, expertise and plant and equipment to carry out the works as specified below.
Generally the process of constructing soilcrete columns comprises the drilling of a hole through the material to be treated to the required depth,
the erosion of the surrounding material by high velocity jetting with cementitious grout (possibly using air and also water to facilitate the process)
and the simultaneous rotation and withdrawal of the drill string to form the soilcrete columns. Surplus materials need to be continuously removed
from the platform. The plant and equipment required need to be matched to meet the demands during execution to meet the continuity
requirements of this technique. Positioning, resourcing and good maintenance are similarly essential in achieving the desired product.
The Contractor shall construct trial columns as specified herein and shall allow for the Engineer’s assessment of these columns. Further objectives
are the determination of the rotation and withdrawal rates of the monitor required to achieve the specified minimum diameter of the columns.
Exposure of the completed trial columns after the specified curing period to ascertain whether the soilcrete columns meet the specified
requirements regarding diameter and uniformity shall generally be required as well as the execution of tests and measurements for quality
assessment purposes.
The commencement of the production columns may only commence when the Engineer has given his written acceptance of the designs for which
the Contractor is responsible in terms of the Contract Documentation, the Contractor’s method statements, approval of plant and equipment, spoil
disposal arrangements and the Contractor’s successful installation and testing of the trial column.
A12.3.3.5 Compaction grouting

Compaction grouting is the in-situ soil compaction process whereby the density or bearing capacity of soils are improved by the injection of a thick
cementitious grout under pressure. The technique is frequently employed to address settlement under existing foundations and for the ground
improvement for new structures and embankments.
The injected grout forms an enlarged bulb or series of bulbs while displacing the soils thereby increasing its density. Generally, the aim is to form
columns of grout bulbs from the surface or just below an existing foundation to such depth that competent materials /conditions are encountered.
The grout is pumped through driven or drilled in grout pipes and the compaction grouting can be performed from the top down (downstage grouting)
or from the bottom up (upstage grouting). With downstage grouting the uppermost bulb is formed first and after initial set has taken place the grout
pipe is drilled through the bulb to a lower stage where the next bulb is created. With upstage grouting the bulbs are formed as the grouting tube
is withdrawn in typically 500mm increments.

A12.3.3.6 Dynamic Compaction (DC)/ Dynamic Replacement
Dynamic Compaction (DC) is the process whereby density of in-situ soil is improved by dropping a large weight or pounder from great height onto
the soil to be compacted. Depth of improvement is typically 6,0–8,0 m.
Shock of the falling weight may cause damage to nearby structures/services and potential impacts must be determined.
Dynamic replacement is a technique whereby in situ soft/loose soils are displaced by stone columns driven into the soils by dynamic compaction. It is
used in very soft cohesive with high moisture contents making compaction by conventional means impossible. The columns of stone are driven by
a pounder as in Dynamic Compaction
A12.3.3.7 Rapid Impact Compaction (RIC)

Rapid Impact Compaction (RIC) of in situ soils is achieved by repeatedly dropping a large weight or pounder of between 9 and 12 tonnes from a
height varying from 1,0-1,5 m, at a high frequency (about 40 blows per minute, depending on machinery employed), onto ground to be compacted.
Depth of improvement is typically 3,0-5,0 m.
RIC is carried out by impacting blows on a grid, triangular (3 prints) or square (either 4 prints or a 5-print sequence in which one is located in the
middle of the 4). Ram size varies from 1,0-1,5 m diameter and grid size varies from 2,0-4,0 m. Up to 50 blows per imprint may be required to
achieve specified densification.
Material may either be compacted as is or stone columns may be constructed by placing selected stone at regular intervals in the created voids
and continuing compaction thereon driving stone into the substrata. Stiffness of these stone columns needs to be controlled.
A12.3.3.8 Vibration compaction

Vibration Compaction is the process whereby in situ soils are compacted by vibrating immersion probes inserted into the soil to increase relative
density, stiffness and strength thereby reducing settlement as well as improving resistance to liquefaction. Vibration may have either horizontal or
vertical amplitude and brings soil particles into a state of suspension allowing for their rearrangement and densification. Water jets assist
penetration of vibrator into the ground and rearrangement of soil particles. Degree of soil improvement is largely dependent on grading of soil,
natural resonant frequency and level of energy available. Vibration compaction consists of:
Vibro-compaction is a technique, designed to induce compaction of granular materials at depth. The basic principle behind the process is that
particles of non-cohesive soils can be rearranged by means of vibration.
Vibro-replacement is a technique derived by further developing the vibro-compaction process. Soils such as pure silts or mixed deposits of silt,
and/or sand are improved by lateral displacement initially induced by probe insertion and further densified by the addition of coarse aggregate to
create a stone column. Soil improvement relies on higher stiffness and shear strength of stone columns which act compositely with the surrounding
soil.
A12.3.3.9 Underpinning
Underpinning is the process of staunching settlement of a structure post-construction. Underpinning may be accomplished by extending existing
foundations in depth or in area to more supportive substratum or distributing load across a greater area, supplementing the support by providing
additional piles or micro-piles or by ground improvement beneath existing footings.
Underpinning may be necessary when:
- Original foundations have insufficient bearing capacity/stability. Properties of material supporting the foundation may have changed (possibly
through seepage or soil particle distribution or pore water dissipation),
- Geotechnical characteristics misdiagnosed during investigation/design,
- Construction of nearby/adjacent structures necessitates excavation of existing foundations,
- To increase depth or load capacity of the structure It is more economical to upgrade the present structure's foundation than to construct a new
one,
- Earthquake, flood, drought or other natural causes have caused the structure to move, thereby requiring additional work in the form of
underpinning.
A12.3.3.10 Preload monitoring (stability monitoring of fills under construction)

Road embankment fills constructed over potentially compressible and weak ground require special construction procedures to be implemented to
ensure their stability both during and post-construction. These may include slow construction or staged construction possibly with surcharge
loading, generally in advance of adjacent conventional roadworks, preload monitoring is the process of measuring settlements, pore pressures
and other parameters in order to ensure stability is maintained during construction by providing time for settlement and pore pressure dissipation.
Monitoring can consist of:
- Measurement of settlement of the fill embankment relative to the surrounding surface,
- Pore water pressures in underlying materials subject to load,
- Load cells/ earth pressure cells encompassed within constructed fill (e.g. Gloetzl cells),
- Ongoing monitoring of the embankment side slopes with inclinometers.
A12.3.3.11 Basal reinforcement

Basal reinforcement may be required where soft deep deposits below fills make removal uneconomical or over undermined areas and karst
regions where soft or voided zones require bridging. This basal reinforcement usually comprises geosynthetics in the form of polymeric or steel
reinforcement to prevent embankment distress. The tensile capacity of the geosynthetic in conjunction with the fill above can be used in the
repair/bridging of sinkholes or undermined areas. Void sizes up to 5,0 m may be treated (provided the fill thickness is at least 2,0 m thick) but
specialised applications are necessary for larger voids.
Where the void or soft zone size exceeds 5,0 m, steel cables are usually used in conjunction with a ring beam and appropriate matting to ensure
material retention.
Basal reinforcement can also be addressed employing other sophisticated techniques such as included in this and other sections in this chapter,
e.g. piling, compaction grouting, jet grouting, etc.

A12.3.4.1 General
The Contractor shall design the concrete and/or grout used in carrying out the works as specified. Mix designs shall be complete, be presented
on the required forms and shall be presented to the Engineer with samples of all the constituents as required at least 6 weeks prior to placement
Where design by the Contractor for any specialised/proprietary technique to be carried out is, in terms of the Contract Documentation, responsibility
of the Contractor, all aspects given below shall be taken into consideration in carrying out these obligations.
The following shall normally be specified (where applicable) by the Engineer and reflected in the Contract Documentation:
- Techniques and methods to be followed,
- Site specific requirements,
- Drilling methods,
- Limits of area and depths to be treated,
- Grout mix composition,
- Grout strengths, column characteristics, post treatment properties, durability and any other deliverables as may be appropriate,
- Spacing of treatment positions,
- Sequence of treatments,
- Permissible limits (pressures, flow rates),
- Quantities of grout/other materials to be injected/used,
- Monitoring of works,
- Quality and workmanship requirements,
- Measurable properties to be achieved over the life span of the project,
- Environmental and safety requirements specific to techniques to be executed,
- Monitoring and record keeping requirements.
The following information will generally be provided in the Contract Documentation:

- A definition of the objectives and control criteria,
- Investigation data including subsurface geological information, hydrological data and geotechnical parameters,
- Test data, borehole logs and recovered core samples,
- Limitations including information on subsurface services,
- Availability of materials on site.
The following additional aspects, where applicable shall also be addressed:

- Finishing off of treatment area to specified lines and levels,
- Whether materials are to be removed, removed and replaced by other materials,
- Processing of materials and all other measures to be carried out in meeting requirements as specified in the Contract Documentation.
The Contractor shall provide a quality management plan indicating his proposed quality assurance testing program which shall allow for testing at
each treatment position. Testing methods to be employed shall be as specified in the Contract Documentation.

Where so specified the Contractor shall prepare a detailed construction proposal/design detailing all plant, equipment and materials to be
employed in meeting the geotechnical grouting objectives and performance requirements detailed in the Contract Documentation. In compliance
herewith the Contractor shall address all the aspects given in Clause A12.3.4.1 above.
The Contractor shall be responsible for the design of a suitable cementitious grout mix for the grouting which shall be presented for approval by
the Engineer with due consideration of the following:
- Availability of cementitious products in the quantities required for production,
- Achievement of specified characteristic strength in the mix,
- Consistency and pumpability of the grout.
The following procedure shall be applicable:
- Obtaining samples of mix constituents,
- Carrying out mix designs,
- Production of trial mixes in laboratory to allow for sampling and testing of grout,
- Production of trial mixes by production plant to allow for sampling and testing of grout,

- Carrying out adjustments to mix designs as may be required and repeating laboratory and production plant trial mixes to allow for sampling
and testing of grout,
- Obtaining Engineer approval of the mix.
Note that the above design shall be carried out by competent personnel following relevant approved/ specified mix design procedures and SANS
methods for sampling, curing and testing procedures. Relative density as well as fluidity of various mixes shall be determined to provide a basis
for ongoing quality assurance during production grouting.
The Contractor shall submit his proposed cementitious grout mix design for geotechnical grouting accompanied by all relevant information for
approval by the Engineer 6 weeks before programmed use in permanent works.
It should be noted that grouting will only be permitted to proceed if the Engineer is satisfied that the mix meets minimum performance criteria
specified including 28 day characteristic strength of cementitious grout as specified in the Contract Documentation. Any changes to the mix after
the Engineer’s approval shall only be permitted if approved in writing by the Engineer.

Where so specified, the Contractor shall prepare a detailed construction proposal/design detailing all plant, equipment and materials to be
employed in meeting jet grouting objectives and performance requirements detailed in the Contract Documentation. In compliance herewith the
Contractor shall address all aspects given in Clause A12.3.4.1 above:
The Contractor shall be responsible for design of a suitable cementitious grout mix for jet grouting which shall be presented for approval by the
Engineer with due consideration of the following:
- Availability of cementitious products in quantities required for production,
- Achievement of specified characteristic strength in the mix,
- Consistency and pumpability of grout,
- Eroding efficiency of grout.
- Obtaining samples of mix constituents,
- Carrying out mix designs,
- Production of trial mixes in laboratory to allow for sampling and testing of grout,
- Production of trial mixes by production plant to allow for sampling and testing of grout,
- Carrying out adjustments to mix designs as may be required and repeating laboratory and production plant trial mixes to allow for sampling
and testing of grout,
- Obtaining Engineer-approval of the mix.
Note that the above design shall be carried out by competent personnel following relevant approved/ specified mix design procedures and SANS
methods for sampling, curing and testing procedures. Relative density as well as fluidity of various mixes shall be determined to provide a basis
for ongoing quality assurance during production jetting.
The Contractor shall submit his proposed mix design for the cementitious mix for jet grouting accompanied by all relevant information to the
Engineer for approval 6 weeks before programmed use in permanent works.
specified including 28 day characteristic strength of cementitious grout as specified in the Contract Documentation. Any changes to the mix after
Engineer-approval is obtained shall only be permitted if approved in writing by the Engineer.

The Contractor shall be responsible for design of a suitable cementitious grout mix, which shall be presented for approval by the Engineer 6 weeks
before programmed use in permanent works.
The Contractor shall prepare a method statement detailing all plant, equipment and materials to be employed in meeting compaction grouting
objectives and performance requirements detailed in the Contract Documentation. In compliance herewith the Contractor shall address all aspects
given in Clause A12.3.4.1 above. A lead time as per Table A12.3.3-1 is required for this information.
specified including 28 day characteristic strength and slump of the cementitious grout as specified in the Contract Documentation.
This submission shall provide the following details as a minimum:
- Cement type and class,
- Water quality,
- Sand grading, Atterberg Limits and source,
- Admixture type and properties (if proposed),
- Quantities of above,
- Pressures to be used,
- Methods used, i.e. up-or down stage grouting,
- Sequence of operations,
- Alternative procedures should certain specified criteria not be met.

The Contractor shall conduct trials before production grouting commences to confirm exact mix proportions and additives, to produce a stiff,
pumpable mortar which achieves compaction of the soil mass into which it is injected, as specified in the Contract Documentation.
A12.3.4.5 Dynamic Compaction (DC)

Where so required, the Contractor shall prepare all necessary drawings and specifications, plus method statements detailing all plant, equipment
and materials to be employed in meeting dynamic compaction objectives and performance requirements stipulated in the Contract Documentation.
This may include but is not limited to bearing capacity, stiffness (E-modulus) and density requirements of soil horizons over targeted treatment
areas.
The Contractor shall address all relevant aspects given in Clause A12.3.4.1 Geotechnical grouting above as well as the following (as may be
applicable) in his proposal:
- Drawings indicating treatment grid, methodology, equipment to be used, and sequence to be followed complete with interim phases in
achieving specified properties at any point,
- If rock columns are specified, dimensions of such, extent thereof and materials to be used.
- Source of materials and properties thereof, as tested by an approved laboratory shall also be included.
The following information will generally be provided by the Engineer in Contract Documentation:
- Area and depth of treatment/ground improvement,
- Performance requirements (bearing capacity, E-modulus/stiffness, density),
- Acceptance control requirements,
- Approved test methods,
- Protection of works,

As for Clause A12.3.4.5 above.

The following shall be addressed in the Contractors proposed method statements:
- Drawings detailing proposed treatment grid,
- Methodology to be followed,
- Equipment to be used,
- Sequence to be followed. If rock/gravel columns are to be provided, dimensions, materials to be used, source of these materials and properties
thereof as tested by an approved laboratory shall also be included.
- Finishing-off of treatment area to specified lines and levels, whether materials are to be removed, removed and replaced by other materials,
processing of materials and all other measures to be carried out in meeting requirements as specified in the Contract Documentation.
The method statement shall provide a quality management plan indicating proposed quality assurance testing program at each treatment position.
Testing methods to be employed are specified in the Contract Documentation.
The following information will be generally provided in Contract Documentation:
- Area and depth of treatment/ground improvement,
- Performance requirements (allowable bearing capacity, Stiffness E-modulus),
- Proposed test methods,
- Process control requirements,
- Protection of the works.
The Contractor shall be responsible for the design of all construction items necessary for the underpinning including, but not restricted to:
- Suitable cement mix design
- Excavation techniques and shoring
- Micropile type and installation techniques
- Grout and / or resin mix design and injection system.

All shall be presented for approval by the Engineer.
The Contractor shall prepare a method statement detailing all plant, equipment and materials to be employed in meeting the underpinning
objectives and performance requirements detailed in the Contract Documentation in compliance herewith the Contractor shall address all the
aspects given in Clause A12.3.4.1 above and lead time requirements as per Table A12.3.3-1.
Mass concrete; structural concrete; and grout injection underpinning shall only be allowed to proceed if the Engineer is satisfied that relevant
mixes the minimum performance criteria specified including the 28 day characteristic strength and slump of the concrete as specified in the
Concrete mix design submission shall provide the following details as a minimum:
- Cement type and class
- Water quality
- Sand grading, Atterberg Limits and source
- Admixture type and properties (if proposed)
- Quantities of the above.
All cementitious mix designs for concrete; grout and resins shall be carried out by competent personnel following the relevant approved/ specified
mix design procedures and, the case of cement items, SANS methods for the sampling, curing and testing procedures. The Contractor shall
submit his proposed mix design for all cementitious products and all relevant information to the Engineer for approval.
A12.3.4.9 Preloading
The Contractor, where so specified, shall prepare a detailed construction method statement detailing all plant, equipment and materials to be
employed in meeting the preload monitoring objectives and performance requirements detailed in the Contract Documentation.
A12.3.4.10 Basal Reinforcement

If so specified in the Contract Documentation the Contractor shall carry out the design of the basal reinforcement in accordance with the specified
criteria and the appropriate requirements in Clause A12.3.4.1 above. The Contractor shall submit detailed designs including calculations and
construction drawings to the Engineer for approval. The latest version of SANS 8006 shall be used for design. Alternatively limit equilibrium or
finite element formulations may be used but the Contractor will be required to provide evidence that the designers are well-versed in this field.
Both serviceability and ultimate limit states shall be evaluated. Reliability predictions shall also be made.
A12.3.5 MATERIALS
The Contractor is responsible for the design of the grout. Typical grout types are listed below.
a) Cement/water grouts
Cement used in grout shall be CEM I or CEM II (SANS 50197-1) or such other cements as specified in the Contract Documentation. Depending
on the grouting method employed, the Engineer may allow or specify use of certain additives such as bentonite to reduce bleeding, improve
penetration, to vary viscosity or to improve pumpability of the grout. Where large cavities are to be filled, the Engineer may allow or specify use
of fillers, sands or gravels provided specified performance criteria are met. These shall be free of deleterious materials and meet criteria for use
as aggregates in concrete (SANS 1083).
b) Bentonite/blended cement grouts
Bentonite grouts, either neat, or blended with cement, are finer than pure cement grouts but do not develop the same strengths.
c) Chemical grouts
Chemical grouts enable better penetration than cement or bentonite-based grouts.
These include:
- Sodium Silicate,
- Acrylamides,
- Ligno-sulphonates,
- Phenoplasts,
- Aminoplasts.
d) Speciality grouts
Specialised grouts such as epoxy resins, polyurethanes and resin silicates may be used in specialist applications and shall be detailed in Contract
Documentation.
All grout materials shall be stored under roof and protected from weather and contamination.

Materials for the cementitious grout used in jet grouting shall be as follows:

a) Cement
Cement used in cementitious grout shall be CEMI or CEMII or such other cements as specified in the Contract Documentation.
b) Water

Materials for the cementitious grout used in compaction grouting shall be as follows
a) Cement
Cement used in compaction grouting shall be CEMI or CEMII,
b) Water
c) Sand
Sand shall be clean, non-plastic, non-angular and well-graded particles sized from 0,06 – 2,0 mm.
d) Bentonite
Bentonite shall be OCMA grade (Oil Companies Material Association) and comply with API 13A.
A12.3.5.4 Dynamic compaction

Materials for backfilling of craters or depressions created by dynamic compaction shall, unless otherwise specified in the Contract Documentation,
meet the requirements for G7 material as defined in Chapter 4. However, where stone columns are required, dump rock/ blast rocks shall be used
as specified below:
- To increase stiffness of in-situ soils:
- UCS greater than 40 MPa but less than 75 MPa,
- Maximum size 300 mm,
- Percentage passing the 0,075 mm sieve less than 5 %
- To increase stiffness and provide drainage for dissipation of excess pore pressures
- UCS greater than 100 MPa,
- Maximum size 300 mm,
- Percentage passing the 0,075 mm sieve less than 5 %.
Dump rock for stone columns shall be obtained from a suitable source, approved by the Engineer. It shall be un-weathered, sound and durable.
Mudrock, shales and other rapid weathering rock types shall not be used.
A12.3.5.5 Rapid impact compaction

As for A12.3.5.4 above.

Crushed stone to be used for replacement material shall be manufactured / crushed from approved un-weathered, sound durable rock, with
grading of material in a range from 8,0 mm to 40 mm and a specific gravity greater than 2.4.
Materials for underpinning shall consist of:
a) Concrete
All concrete used for underpinning purposes shall comply with the requirements given in Section A13.4 of Chapter 13 unless otherwise specified
in the Contract Documentation. Water used for batching of grout shall comply with SANS 241 and water for concrete shall comply with SANS
51008.
b) Chemical grouts
Chemical grouts may include but not be limited to:
- Sodium Silicate,
- Acrylamides,
- Ligno-sulphonates,
- Phenoplasts,
- Aminoplasts
c) Speciality grouts
Specialised grouts such as epoxy resins, polyurethanes and resin silicates may be used in specialist applications as detailed in the Contract
Documentation.

d) Micropiles
Materials for micropiles shall be as specified in the Contract Documentation.
A12.3.5.8 Preload monitoring

a) Filter sand for piezometers
Filter sand used to fill voids between drilled hole sides and piezometer porous element surrounds shall be clean, siliceous sand from an approved
source 0,06 TO 2,0 mm with less than 5 % smaller than 0,425 mm and less than 5 % greater than 1,18 mm. The sand shall also comply with the
b) Bentonite pellets for seals
Bentonite pellets for seals shall be as specified in the Contract Documentation.

a) Reinforcement
(i) General
Reinforcement shall be axially stiff and able to absorb tensile-, shear- and bending loads and shall sustain the design loads at strains
greater than 1 %.
(ii) Polymeric reinforcement
These are generally manufactured from high density polyester, polypropylene or high density polyethylene with strain-at-break values which vary
from 8 to 11 %. Ultimate tensile strengths range from 50 to 1 600kN with a design strength developed at 4-6 % strain. They may be uni-or bi-
directional.
(iii) Steel reinforcement:

Steel reinforcement encompasses metallic strips, ladders, bars, grids, woven wire meshes, and rods used in geotechnical Engineering
for the strengthening and reinforcement of soils and fills.
Unless otherwise specified, steel wire shall comply with the requirements of SANS 675: 1997. 3,0 mm diameter wire with an ultimate
tensile stress which varies between 350 and 575 MPa with a strain at break which exceeds 10 % shall be used in the manufacture of
netting where specified. Hexagonal woven wire mesh is constructed by twisting continuous pairs of wires through three one half turns
(commonly referred to as double twist) which are then interconnected to adjacent wires to form hexagonal openings of 80 mm breadth
over the 3,0 m width. Wire shall be corrosion protected. Zinc coating shall be applied as per the requirements of Table 3 of SANS
121 at a mean coating thickness of 45 microns for elements less than 3,0 mm in diameter and 55 microns for elements greater than
3,0 mm diameter or protected with aluminium/zinc (Galfan) coating. Galfan shall be applied to generate a coating mass of 245 g/m2
or a thickness of 35μm and shall be tested for a) adhesion by observing that it does not flake or crack when wrapped six turns around
a 12 mm diameter mandrel and b) for ductility in that it does not show any signs of fracture when wrapped and unwrapped at least 8
times around a 3,0 mm diameter wire at a rate of less than 15 turns per minute.
Where specified high tensile steel wire shall be used. The required ultimate tensile stress shall be indicated (generally between 1000
MPa and 2000 MPa) with a strain at break which exceeds 10 %. The wire shall be corrosion protected with a zinc coating applied as
per the requirements of Table 3 of SANS 121 at a mean coating thickness of 45 microns for elements less than 3,0 mm in diameter
and 55 microns for elements greater than 3,0 mm diameter.
b) Overlap sand
Where so specified overlap sand shall be used as infill between successive rolls of geosynthetic and shall comply with the requirements of coarse
river sand as per Clause A3.1.5.2b) of Chapter 3.
c) Backfill
Backfill shall comply with the requirements of Table 5 of SANS 8006 or as detailed in the Contract Documentation.
d) Joining materials
Should material require joining to ensure continuity, this must be done to satisfaction of the Engineer. Interweaving, bodkin joints, sewing and
many other methods may be used. Testing shall be conducted to prove efficacy. This may also be achieved via overlapping and filling the
interface with 20 mm thick overlap sand. Overlappling shall be carried out in accordance with Clause A12.3.7.9(c).

all materials.
b) Grout mixing equipment
A high speed double drum colloidal mixer shall be used to produce a homogeneous mix suiting the particular injection method. This mixer shall
be fitted with a suitable capacity holding tank to ensure continuity of operation and fitted with agitators capable of preventing any segregation or
lump formation.

c) Grout pumps and injection equipment
Positive displacement grout pumps of adjustable rate, together with injection equipment, shall be compatible with the intended injection technique.
Pumps shall produce sufficient pressure/volume for successful injection.
d) Ancillary equipment
All ancillary equipment (hoses, packers, couplings, sleeves, injection pipes, nozzles etc.) required to execute the specified grouting technique,
shall be fit-for-purpose.

a) Drill rig and ancillary equipment
Drill rig and equipment shall be of a type and capacity suitable for required hole inclination, diameters and depths and for lowering, raising and
rotating the jet grouting monitor at rates and to depths required to perform works as specified herein and as shown on the Drawings. Drill rigs shall
furthermore be equipped with automated controls to regulate and control extraction rate, rotation rate (rpm) and shall have electronic pressure
gauges for all fluids injected. Extraction shall be a smooth operation and not a staged lifting operation.
The monitor shall be appropriate to the process, i.e. single-double or triple system and be fitted with appropriate injection nozzles /injection points.
Drill rods shall have required number of conduits to convey pressurised grout, air and water as may be required without any pressure loss and/or
leakage to achieve the specified product. The Contractor shall select type of drill bit appropriate to materials through which he has to drill.
Should the type of rig and or equipment be inappropriate to requirements or conditions on site, these shall be replaced by suitable equipment at
the Contractor’s cost.
b) Grout mixer
The mixer used for manufacture of grout for jet grouting purposes shall be a high-speed, high-shear colloidal mixer of sufficient capacity to ensure
an adequate supply of grout as required for continuous production. This mixer shall be fitted with calibrated load cells to enable accurate weigh-
batching of cementitious materials. Holding tanks shall be fitted with an agitator to capable of maintaining colloidal condition and fluidity of the
mixed grout. Outlets shall be fitted with a suitable filter with openings of ≤ 1,0 mm, to remove any aggregations.
c) Injection equipment
(i) Grout pump
Grout pumps shall be of sufficient capacity (up to 600 bar) to ensure adequate supply of grout at specified pressure to jet grouting
monitors. Pumps shall be fitted with a recently calibrated pressure gauge with a dial of > 150 mm diameter enabling accurate readings
to the nearest 10 bar and a valve which can be locked off without pressure loss.
(ii) Compressor
Compressors shall be capable of producing compressed air at pressure and flow rates determined in trials to produce the specified
end product.
(iii) Water supply
Water tanks shall have sufficient capacity to ensure adequate supply during a working shift. Pumps used shall be of sufficient capacity
to provide required flow and pressure.
(iv) Hoses
Hoses used shall be appropriately rated for pressures required.

Compaction grouting equipment shall comprise the following:
all materials.
b) Pumping units
- A stationary or truck-mounted mobile concrete/grout with 20m3/h pump capacity,
- Suitable hoses and connectors for required pumping pressures.
Pumps, hoses and supply lines shall be capable of maintaining pressures up to 10 MPa. Pumps shall be capable of displacing zero-slump grouts,
with displacements as low as 15 litres/minute. Pumps shall be equipped with suitable, calibrated (calibration certificate required) pressure gauges
for recording pumping pressures up to15 MPa and fitted with a dial greater than 150 mm diameter enabling accurate readings to the nearest
100kPa and a valve which can be locked-off without pressure loss.
c) Compressor
Compressors shall be capable of producing compressed air at pressures and flow rates determined in trials to produce the specified end product.
d) Water supply
Water tanks shall have sufficient capacity to ensure adequate supply during a working shift. Pumps used shall be of sufficient capacity to provide
required flow and pressure.
e) Hoses

f) Grout sleeves
Grout sleeves shall consist of high-pressure seamless steel pipes, to suit required hole-diameter and pumping pressures. These shall be inserted
to desired depth in bored holes, fitted with a reusable coupling compatible with the pumping unit.
g) Slump cone
The Contractor shall maintain slump-measuring equipment on site in good condition at all times.
A12.3.6.4 Dynamic compaction

Equipment typically used for dynamic compaction includes:
- A heavy weight, 7-16 tonne pounder,
- High capacity crawler mounted cranes fitted with a linear winch to lift pounders to heights up to 22 m and release them to ram in-situ soil,
- Conventional earthworks equipment and plant for level adjustments and compaction of backfilled materials.
Selection of pounder and drop height depends on site conditions and required compaction depths.

The equipment for Rapid Impact Compaction (RIC) comprises:
- A heavy weight pounder of 9-12 tonnes and 1,0-1,5 m diameter,
- A hydraulic mechanism capable of lifting and releasing the pounder to free-fall through heights of up to 1,5 m onto material to be compacted
at a rapid frequency (greater than 40 blows/minute).
- A suitably modified about 45 ton excavator, to carry RIC mechanism,
- Cab-mounted electronic instrumentation for remotely monitoring ram penetration/blow, enabling the operator to successfully guide operations
to ensure desired number of blows are applied to achieve desired densification.

Equipment comprises a vibrating section (probe) coupled via a flexible isolator to follower sections/rigid extension tubes wherein flexible pipes
housing water and hydraulic pipes and electrical wiring are located. Vibrator comprises electric or hydraulic motor driving eccentric weights.
Weights rotate about a vertical axis so that amplitude of vibration is in a horizontal plane.
Vibrators shall have fins/vanes to resist rotational forces induced by the motor. Extension tube/s shall provide sufficient reach to enable treatment
to required depth. Multiple water jets, an upper and lower one, facilitate penetration and temporary liquefaction.
A crane is used to position, lower and raise the assembly.
The following shall generally be specified:
- Power (kW)
- Depth of treatment (m)
- Operating frequency (Hz) (or rpm)
- Operating centrifugal force (kN)
- Amplitude (mm)
- Maximum pressure (bar)
The Contractor shall in his method statements provide comprehensive details of all plant and equipment, appropriate to the specified works before
construction commences. Such equipment shall cover demolition and/ or removal of existing materials or infrastructure, provision of temporary
support as well as any other activities whether temporary or permanent that may be required to facilitate the works to be carried out in terms of
A12.3.6.8 Preloading
a) Settlement monitoring by survey methods
Survey equipment for monitoring of embankment fill by precise levelling shall be calibrated and in good working order.
Settlement plates to be installed shall comprise 20 mm thick metal discs with diameter greater than 1,0 m and have perpendicularly-attached
extendable 1,0 m long steel rods greater than 25 mm, or pipes, Targets painted at rod tops shall provide for accurate survey. Steel rods/pipes are
extended with couplings as filling of embankments progresses .
b) Settlement monitoring by magnetic extensometers
Magnetic extensometers provide a means of measuring settlement or heave at a point or series of points in the subsurface. Extendable access
tubes are installed in predrilled holes. A datum ring magnet is installed about 2,0 m from the lower end of the tube. Spider magnets, temporarily
held in place along the tube, are used within the subsoil. Plate magnets within the fill can be placed during construction. Once in position the
spider magnets are released. The hole is backfilled with a bentonite: cement mix of strength equivalent to surrounding material.
Readout devices shall consist of a nickel-plated brass probe containing a reed switch encapsulated in silicone rubber. Probes shall be connected
via a nylon coated steel tape to a reel buzzer. Instruments and all ancillary equipment shall be approved by the Engineer before being used.
Combined inclinometers and magnetic extensometers which provide means for measuring both vertical settlement and horizontal displacement
at a series of points below the ground surface may be considered by the Engineer.
c) Slope stability monitoring
(i) Inclinometers
Measurement of lateral movement at selected depths at a position on the embankment is conducted by means of sending an
inclinometer torpedo down inclinometer tubing installed in a borehole or placed horizontally across the embankment during
construction. This torpedo has an electronic accelerometer capable of measuring deflection of the torpedo (and tubing) which is
coupled via an electric cable to a remote readout unit. The instrument shall be approved prior to use by the Engineer and shall have

a calibration certificate, less than 12 months old issued by manufacturer. Tubing shall be installed as specified in Contract
Documentation by competent experienced personnel.
d) Stability monitoring
(i) Pore water monitoring - standpipe piezometers
The piezometer tip shall be as specified in the Contract Documentation. U-PVC tubing shall be jointed together and to the porous
element by threaded couplings and be leak proof. Depth to water shall be measured using an electronic dipmeter.
(ii) Pore water monitoring - pneumatic piezometers
Pneumatic piezometers shall be of the high air-entry ceramic type with an average pore diameter of 1µm in marine brass or stainless
steel bodies. Piezometers shall be connected to colour-coded nylon tubing (flow and return pipes) marked every 3,0 m. These pipes
shall be without joins and either fitted with quick release couplings or be taken to a terminal panel fixed inside a lockable steel cabinet.
Readout units shall be as specified in Contract Documentation and shall in addition to pressure transducers have a rechargeable gas
reservoir, return and flow indicators, a flow control valve and be fitted with quick-release self-sealing leads for connection to supply
and return manifolds of the terminal panel. The Contractor shall provide facilities for the recharging of the nitrogen reservoir. The
piezometer system shall be capable of measuring water pressures to an accuracy of approximately 0,2 m head in the range 0-100 m
head of water.
(iii) Soil pressures/load monitoring
Load cells are encompassed within constructed fills (e.g. Gloetzl cells). These load cells operate hydraulically and are placed within
fills at selected positions to monitor earth pressures during construction and are connected via special tubing to hydraulic readout
units.
e) Drilling equipment
Drilling equipment used for boreholes for installation of magnets or piezometers shall be in good working order shall be capable of providing a
stable hole to the required dimensions, tolerances, direction and inclination Both rotary and percussion drilling methods may be used unless
otherwise specified in project documents. Boreholes shall be cased full depth. The drill rig/equipment shall be able to install and remove casings
as may be required during drilling operations, without loss of direction or inclination, in all materials . The method of forming boreholes and
advancing casing shall be approved by the Engineer before commencement of the works. Drilling aids, muds or additives may only be used if
approved by the Engineer. Where piezometers are to be installed, additives, muds or drilling aids shall be used. Should the type of rig and/or
equipment prove inappropriate for the requirements or conditions on site, these shall be replaced by suitable equipment at the Contractor’s cost.

Mechanised plant may be used in unrolling the geosynthetic rolls but it is more usual to use manual labour. If fastening or stitching equipment is
used, these shall comply with the relevant OHS regulations. Normal construction machinery is used for any earthworks.

a) General
Percussion drilled holes are generally used in grouting applications. Flushing media and drilling techniques used shall not be detrimental to any
subsequent grouting operation (particularly regarding changes in permeability at the point of injection).
b) Trials
The Contractor shall carry out a series of trials to ensure his methods and equipment can effectively deliver the required end product. These trials
enable adjustments to be made to proposed construction methodologies. Trials successfully carried out as specified and accepted by the Engineer
will be measured and paid for under appropriate items and tendered rates.
c) Grouting process
(i) Drilling
Holes shall either be vertical or inclined as specified. After drilling, holes shall be air-flushed to remove detritus, loose material and to
open cracks/fissures. Completed holes shall be plugged if grouting does not immediately follow cleaning. Where holes are blocked
/ collapsed or deviate unacceptably, these shall be re-drilled at the Contractor’s expense.
(ii) Grout mixing
Where bentonite is used it shall be fully hydrated to the Engineer’s satisfaction before mixing with other binders. Mixing shall be
batched using calibrated measuring devices meeting the Engineer’s approval. Grout provided shall be free of stones, lumps, foreign
oils or any other debris.
(iii) Grout injection
Proposed patterns and sequences are indicated in Contract Documentation. The Contractor’s method statement shall conform
thereto. Method of placement shall be determined by ground conditions, specific site requirements and type of grout used shall follow
the basic approach listed below:
- Injection in unsupported boreholes in stable ground,
- Injection via sleeve pipes placed in temporary cased boreholes in unstable ground,
- Injection through drill string in unstable ground (pre-grouting phase followed by (i) or(ii),
- Injection through sleeve pipes or drilled holes into fissures or cavities.
Grout injection shall either be:

- Single stage, whereby the hole is drilled to its full depth and grouting is completed over full hole length,
- Multiple stage, either be done upstage or downstage,
- Downstage, where drilling and grouting occurs sequentially from top in downward stages,
- Upstage, where the hole is initially drilled to its full depth and grouting takes place from lowest point of injection, upwards, using
packers.
For premature choking of grout pipes as a result of Contractor-negligence, the Contractor shall re-drill and equip holes at his own
expense.
d) Monitoring and records
The Contractor shall, on a continuous basis, monitor ground or movements of structures with sufficient accuracy to ensure that any displacements
are within specified allowable tolerances. Proposed methods of monitoring shall be approved by the Engineer before any works are commenced.
Injection parameters (pressure, volume and flow rate) may need to be adjusted to avoid unacceptable deformation.
Daily records shall be kept of all works, materials utilised, and quality control activities carried out in accordance with Contract Documentation and
approved method statements. These records shall be submitted to the Engineer before noon on the following working day. The records shall
include:
- Daily records of all grouting positions, depths of treatment, start and stop times, all grouting parameters used,
- Details of all stoppages, breakdowns and grout injected at each position,
- Cement usage, pumping pressures and other details that may be required for measurement purposes,
- Results of routine consistency tests (flow cone, density tests as specified) carried out on all batches of grout mixed and utilised,
- Details of any holes lost or not completed due to mechanical breakdowns,
- Inadequacy of grout, air or water or any other reason and the treatment thereof,
- Any change in subsurface conditions which affected, or may affect changes in methodology or progress

a) General
The Contractor shall, in carrying out his design obligations, familiarise himself with available information and shall, at his own cost, carry out
whatever further investigations required to provide any further information required in this regard. Such further investigations may include
construction of further jet grouted columns other than the trials provided for in the specifications. Prior written approval by the Engineer shall be
obtained for all additional investigative work by the Contractor.
The Contractor shall provide the Engineer with a method statement detailing all aspects in his design and proposed methodology for carrying out
the works. This method statement shall be the basis for the trials to be carried out as described below.
b) Trials
The Contractor will be required to construct trial columns as specified in Contract Documentation and shall allow for the Engineer’s assessment
of these columns and the Contractor’s construction method statement. These trials provide the Contractor with means to determine optimum
jetting parameters, optimum cementitious content and operational methodologies such as rotation and withdrawal rates of monitors required to
achieve specified minimum diameter of columns. Generally this will include exposure of completed trial columns after the specified curing period
to ascertain whether these soilcrete columns meet specified requirements regarding diameter and uniformity and execution of tests and
measurements for quality assessment purposes.
Trial columns shall normally be outside the area where production or working columns are constructed. Proposals regarding positioning of these
test columns and items to be investigated with each test column, are to be presented to the Engineer for his approval prior to commencement
thereof.
Such items will generally include but are not limited to determination of the following:
- Drilling rate of advance in in situ materials extraction and rotation rates,
- Grout mix composition,
- Pumpability and erosive properties,
- Determining jetting pressures,
- Number and nozzle sizes,
- Testing equipment suitability,
- Column sequence,
- Confirmation that the resultant soil cement products meet specified design criteria,
- Confirmation of the Contractor’s ability to produce the specified product
Operational matters such as waste disposal also need to be addressed.

Each trial column shall have assigned test parameters agreed with the Engineer. Construction of test columns shall be witnessed by the Engineer.
Specifications governing construction of production jet grouting shall apply to construction of test columns.
Trial columns shall be exposed by excavation to depths indicated in Contract Documentation to allow visual appraisal, dimensional and geometric
measurements and for integrity testing Trials successfully carried out as specified and accepted by the Engineer will be measured and paid for
under appropriate items and tendered rates.
The Contractor shall backfill all excavations in layers not exceeding 150 mm with approved materials to the required compaction levels. No
separate payment will be made for such work.
No jet grouted column may be installed at a distance of less than three (3) times column diameter from any exterior point on a known service,
service duct or culvert.
The Contractor shall design his systems to comply with above requirements and shall submit his design with a comprehensive construction method
statement taking into account the outcomes of the trials to the Engineer for his approval. All materials, components and constructional plant shall
be covered.

The Contractor shall not commence with production jet grouting until the Engineer’s approval of the Contractor’s updated construction method
statement. A lead time of two weeks shall be allowed in this regard.
c) Production jet grouting
Production jet grouting shall be carried out using the same equipment, tooling, materials and procedures as for test columns and as per approved
construction method statements and works procedures developed from these trials.
Prior to commencing with production jet grouting, the Contractor shall provide the Engineer with a plan showing his proposed sequence of jetting
for his approval. Note should be taken of subsoil conditions in preparing this schedule as normal practise is to jet alternate columns over the works
area before returning to jet the remaining columns thereby allowing for strength development of jetted soilcrete columns and reducing the possibility
of cross hole interference/grout penetration. Sequencing may also involve a staged approach whereby a strategy is determined to divide the
problem area in zones for separate treatment
Jetting shall only proceed once required grout pressures are attained. Extraction shall be a continuous and not a staged operation. The Contractor
shall configure his equipment to record and continuously show all fluid flows, pressures, rotation speed, depth and extraction rates. Extraction
and rotation rates shall be automatically controlled and recorded during the entire process, by an electronic management system.
The jetting operator shall continuously monitor spoil return and shall halt all jetting, reducing grouting pressures immediately and clear all blockages
to avoid build-up of hydraulic pressure in surrounding materials. On re-commencing jetting, the monitor shall be lowered at least 300 mm below
the stopping point.
The Contractor shall monitor the immediate area, structures and utilities for any signs of change, disturbance or damage or of cross-hole
activity/grout penetration. Similarly surface cracking, bulging or any other change shall immediately be brought to the Engineer’s attention.
If specified in Contract Documentation, the Contractor shall continuously record and plot rate of penetration during drilling of pilot holes so that
positions of different substrata may be identified. Where so specified in Contract Documentation, different soilcrete diameters shall be constructed
in different strata and/or at different positions in the soilcrete columns. Formation of wider diameter columns in the upper portions of soilcrete
columns, often referred to as mushroom heads, may also be specified in Contract Documentation. These will require different parameters to be
used.
d) Loss of hole
Where a hole is lost or abandoned due to mechanical breakdowns or failures or any other causes arising from the Contractors activities or failure
to protect the works, a new hole shall be drilled, entirely at the Contractor’s cost.
e) Reinforcement
Where reinforcement is specified, the Contractor shall install the approved reinforcement in a freshly completed column and secure its position by
approved means to ensure required inclination and cover are maintained.
f) Removal of drilling and jetting spoil
If so specified, payment will be made for removal of spoil where haul distance is in excess of free haul distance.
g) Monitoring and records
The Contractor shall, on a continuous basis monitor ground or movements of structures with sufficient accuracy to ensure that any displacements
are within specified allowable tolerances. Proposed method of monitoring shall be approved by the Engineer before any works are commenced.
Monitoring and logging of all jet grouting operations shall be done by the Contractor and these records submitted to the Engineer before noon the
following working day.
These records shall include:
- Daily records of all jet grouting positions,
- Depths of treatment,
- Start and stop times,
- All jetting parameters used,
- Details of all stoppages, breakdowns and grout injected at each position,
- Daily records of cement usages, pumping pressures and other details that may be required for measurement purposes,
- Results of routine consistency tests (flow cone, density tests as specified) carried out on all batches of grout mixed and utilised,
- Details of any holes lost or not completed due to mechanical breakdowns,
- Inadequacy of grout, air or water or any other reason and the treatment thereof,
- Any change in subsurface conditions which have, or may affect, changes in methodology or progress.
Records shall be in a format agreed with the Engineer.

a) General
Before commencement of production operations and following successful completion of trials as detailed below, the Engineer shall provide the
Contractor with required layout, depth ranges and grouting sequence. No deviation from this shall be allowed unless instructed by the Engineer.
b) Trials
The Contractor shall carry out full depth trials in 500 mm stages at positions indicated by the Engineer to prove adequacy of his equipment,
suitability of his operations, to establish optimum grouting parameters including pressures, pumping rates, and other site specific parameters.
Trials successfully carried out as specified and accepted by the Engineer will be measured and paid for under appropriate items and tendered
rates.
c) Production grouting
Should grouting beneath foundations be necessary, core holes shall be drilled through these elements as indicated by the Engineer on site. Size
of core holes shall be such that appropriate casing can be inserted for subsequent drilling and grouting.

d) Testing
Where specified in Contract Documentation or as instructed by the Engineer, suitable tests to prove depth and efficacy of ground improvement
shall be undertaken. These may include:
- Cone penetration testing or Dutch Cone (CPT) (ASTM D3441),
- Cone penetration testing undrained (CPTU) or Piezocone (ASTM 6001/6067),
- Standard Penetration Test (SPT) (ASTM D1586),
- Dynamic Probe Super Heavy (DPSH) and Dynamic Probe Light (DPL), (BS ISO EN 22476-2 2005)
- Pressuremeter Test (PMT) (D 4719-07),
- Continuous Surface Wave testing (CSW),(seismic technique),
- Dynamic Cone Penetrometer (DCP) (TMH 6)
- Plate Load Testing (PLT) (ASTM1195-94).
e) Advancing casing
Casings shall be drilled/ driven to depths instructed by the Engineer. Once the casing is advanced to required depth, it will be withdrawn some
250 mm.
f) Compaction grout injection
Grout hoses shall be connected to casings and grout pumped through these. Incremental pumping rates shall be <50kPa/minute. Careful
monitoring of grout take and pressure shall be carried out at all times to determine final grout injection pressure of < 4 MPa. Actual pressure
required shall however be that finally assessed by the Engineer to ensure that degree of improvement specified, is achieved, without lifting
foundations or ground surface beyond limits specified in the Contract Documentation. Once final grouting pressure is reached and required
compaction achieved, casings shall be lifted 500 mm and the procedure repeated. This upstage grouting shall be continued to underside of
footings or specified near-ground surface, after which casings will be withdrawn. After completion of grouting at a particular borehole, all grout
spilled on surface shall be removed. Each borehole shall be defined as one set-up station irrespective of number of grouting stages executed.
g) Cautions
The Contractor shall immediately inform the Engineer of any change in subsurface conditions which have or may affect changes in methodology
or progress. The works shall temporarily be stopped, and the Engineer immediately informed should any unacceptable consequence resulting
from the injection process such as uplift of structures or heave of surrounding, area be observed.
h) Monitoring and records
Monitoring and logging of all compaction grouting operations shall be carried out by the Contractor. These records shall include:
- Daily records of all compaction grouting positions, depths of treatment, start and stop times, pressures, details of all stoppages, breakdowns
and volume of grout injected at each position,
- Results of process control slump and cube strength tests,
- Details of any holes lost or not completed due to mechanical breakdowns, inadequacy of grout, air or water supply or any other reason and
proposed remedy/-ies,
- Records shall be submitted to the Engineer before noon the following working day.
A12.3.7.4 Dynamic Compaction (DC)

a) General
Prior to and during operations, vibration monitoring equipment, described in Clause A12.3.8.5a)(ii) is required on site to measure vibrations at
adjacent infrastructure and services, which could potentially be affected by vibrations resulting from dynamic compaction of materials.
A condition survey of the site and any surrounding structures shall be carried out as described in Clause A12.3.8.5a)(i) prior to commencement
of operations and thereafter on a weekly basis until completion of works, including final vibratory rolling with a final evaluation 2 weeks thereafter.
The DC process involves repeated lifting and dropping of pounders on a compaction point. Initial spacing for primary compaction points shall be
shown on drawings.
b) Trials
Trials and field tests shall be conducted on site to determine number of blows required to achieve target/specified density and/or stiffness at each
compaction point and to verify initial spacing for primary compaction points. These may comprise DCP, SPT, DPSH, CSW, PMT and plate load
testing (PLT) as specified and approved by the Engineer. Energy inputs per unit volume shall be determined for consideration and acceptance
by the Engineer. Trials successfully carried out as specified and accepted by the Engineer will be measured and paid for under appropriate items
and tendered rates.
c) Construction process
(i) Normal construction
Initial spacing for primary compaction points shall be indicated in Contract Documentation (typically 6,0 m) but shall be confirmed via
field trials.
Compaction is carried out in three different phases; primary, secondary and an ironing process. Compaction of deepest layers is
achieved with the primary phase. The secondary phase addresses compaction mainly in intermediate layers, while the ironing process
ensures overlapping of initial phases by compacting shallow layers between initial compaction points.
Once the primary phase is complete, work proceeds on secondary phase points. These are positioned midway between primary
phase points.
The final ironing phase of the treated area is aimed at compacting the upper 2,0-3,0 m and achieving a relatively flat, well-compacted
surface. In this phase drop heights are usually limited to 4,0-8,0 m.
After completion of the test phase the Engineer shall determine if performance parameters specified were obtained and if not whether
further works are required.
In certain ground conditions the Engineer may instruct pre-wetting (not to saturation) to facilitate the process. However, in saturated
or near-saturated conditions, pore-water pressure increases with each blow of the pounder. As it becomes excessive, the pounder

has little compacting effect as blows are cushioned by pore water. Slow pore water pressure dissipation may delay completion of the
works. In this eventuality, the Engineer may instruct the Contractor to:
- Modify installation procedure by including a wait period,
- Install vertical drains or,
- Construct stone columns at certain positions or intervals
to facilitate this excess pore water pressure dissipation.
(ii) Dynamic compaction with stone columns/Dynamic replacement
If stone columns are specified, then the compaction process in carried out adding stone as penetration is achieved until “bulking” or
surface-rise around imprint, is observed. No further compaction shall thereafter be required as this condition is indicative of the full
depth being reached.
Monitoring and logging of all dynamic compaction operations shall be done by the Contractor and records shall be submitted to the Engineer
before noon the following working day. These records shall include per treatment point:
- Phase, energy expended, penetration achieved per blow,
- Amount of dumprock used and,
- Any other relevant data which may be required in deriving deformation modulus or stiffness of treated substrata.
A typical record may be as shown in Figure A12.3.7-1.
Figure A12.3.7-1: Typical work pattern
1 1
Tamper 18.2 Mg
2 Drops 6 from 29.0 m

4.6m
working mat 0.9m
1 1
4.6m
Phase 1, 2 passes E = 3.1 2MJ / m2
Phase 2, 2 passes E = 3.1 2MJ / m2
Ironing pass E = 0.42 MJ / m2
E = 6.66MJ /m2
Unit Energy == 6.66MJ / m2 E = 0.73 MJ / m3 = 1.2 Std Proctor

9.154 m

a) General
Positions of RIC points are indicated on drawings. RIC points shall be set out to a tolerance of ± 200 mm. If only RIC without stone columns and
a 5-point grid is specified (4 on the outer edges and one in the middle) then impact compaction shall start with the centre point of the 5 position
grid, followed thereafter with the 4 perimeter compaction points. If 3- or 4-point grids are specified, the order is not prescribed but planning is
necessary to ensure all points are accessible in one sequence.
b) Trials
Trials shall be conducted on site and field tests carried out to determine number of blows required to achieve target/specified bearing capacity
and/or stiffness at each compaction point and to verify initial spacing for primary compaction points. These may comprise DCP, SPT, DPSH, CSW
and PLT as specified and approved by the Engineer. Positions of testing shall be agreed with the Engineer.
rates.
c) Construction process
(i) Without stone columns
The compaction process involves repeated lifting and dropping of the pounder on a compaction point. Specified number of blows or
end limit condition should be applied to each RIC point in turn, before moving to the next point. Where frames for RIC machines only
allow limited depth impact (usually around 1 m) and the end condition is not reached at the depth limit, the imprint shall be filled with
G7 material and re-pounded. This pounding will continue until a set of less than 10 mm/blow is achieved on in-cab instrumentation.
Where specified in Contract Documentation, the Contractor shall construct a capping or compacted soil raft over the treated area to
the criteria specified. Where applicable imprints/craters shall be backfilled with G7 material as approved by the Engineer, ripped to a
depth of 500 mm and compacted to specified density with a padfoot roller with greater than 300 kN centrifugal force, operating in high
amplitude mode at a speed less than 0,5 m/sec. This ensures a homogeneous upper layer.
(ii) Stone columns
If stone columns are specified in soft material then the compaction process in carried out adding stone as progress is achieved until
“bulking” or rise of the surface around the imprint, is observed. No further compaction shall thereafter be required as this condition is
indicative of full depth being reached.
Monitoring and logging of all RIC operations shall be conducted by the Contractor and the records shall be submitted to the Engineer before noon
the following working day. Records shall include per treatment point:
- Number of blows imparted, energy expended, penetration achieved per blow,
- Amount of dumprock used and,
- Any other relevant data which may be required in deriving deformation modulus or stiffness of treated substrata,
- Testing carried out.

a) General
Vibration compaction is the generic term given to two processes, namely vibro-compaction and vibro-replacement.
Treatment areas shall be indicated on drawings and Contract Documentation and shall extend beyond the treatment area by 0.1D where D =
treatment depth.
b) Trials
Optimal spacing of compaction points and treatment parameters shall be determined from trials carried out on site, monitoring soil strengths pre-
and post-treatment across depth range and at varying distances from treatment axis by carrying out in situ tests using preferably CSW but in the
event this is not available, CPT, SPT, DPSH, PMT and PLT.
rates.
c) Vibro-compaction
The vibrator assemblage is placed in position, vibrator set in motion and water jet/s activated. The crane lowers the vibrator, maintaining a vertical
orientation. When the probe reaches full depth lower water jets are shut off and vibrator is slowly raised and lowered into soil which flows into the
cavity created. Density of in situ soil is measured using power input (via electric current or hydraulic pressure) as an index. As material densifies,
the vibrator requires more power to continue vibrating at which point an ammeter or pressure gauge displays a peak in required power.
Raising and lowering is continued in a repetitive cycle as the vibrator is gradually withdrawn in lifts with compaction ensuing until peak amperage
or hydraulic pressure is again reached.
Water jet flow shall be controlled and cut-off when free water reaches surface.
During penetration the following are recorded:
- Depth,
- Penetration rate,
- Withdrawal rate,
- Probe location,
- Volume of added backfill,
- Backfill gradation,
- Ammeter or hydraulic pressure peak, and vibrator assemblage operating frequency.
The upper approximately one metre of soil will not be sufficiently compacted and shall be either removed or compacted by other means as
approved by the Engineer to a density specified in Contract Documentation.

On completion of vibratory compaction activities, densities or other values shall be monitored to ensure specified levels of compaction were
achieved.
d) Vibro-replacement
To create a vibro-replacement column, the oscillating vibrator with its extension tubes sinks rapidly into soil under its own weight, aided by
compressed air and a pull-down facility from a winch. Stone is supplied through a stone tube to vibrator tip with assistance of compressed air. By
moving the vibrator slowly up and down and by vibrations of the machine itself, supplied stone material is pressed into the existing soil. This
process is repeated in short steps up to ground level, leaving, on completion, a compacted stone column surrounded by soil material of enhanced
density. The stone column and the in-situ soil form an integrated system having low compressibility and high shear strength. Excess pore water
pressure easily dissipates through stone columns simultaneously acting as drains.
Vibro-replacement columns installed by the wet method are typically designed to reach diameters between 0,6 and 0,8 m. Based on soil properties
pre-drilling might be necessary. Degree of improvement (settlement reduction and increased shear strength) achieved by vibro-replacement
depends on soils being treated, diameters of stone column installed and installation spacing. Spacing between stone columns is determined in
accordance with design criteria and in situ soil conditions. It typically ranges between 1,5 and 3,0 m.
Crushed stone is fed into the crater formed around the vibrator and a column of crushed stone is formed as the vibrator is cyclically raised and
lowered as the probe is gradually withdrawn. Columns of up to 1,0 m can be created at spacings in the order of 1,5 m to 3,0 m as determined by
field trials.
The upper 1,0-1,5 m of the soil profile generally requires additional compaction utilising conventional compaction methods and equipment to
achieve specified density.
The Engineer may stop the works if it is evident that desired density improvements are not being achieved and shall instruct the Contractor as to
what steps are required to achieve desired results .
e) Monitoring and records
Monitoring and logging of all vibration compaction operations shall be conducted by the Contractor and records submitted to the Engineer before
noon the following working day.
The records shall include:
- Date, time and weather conditions,
- Plant and equipment utilised,
- Number of treatments successfully completed,
- Comments on progress achieved and any snags,
- Stoppages and breakdowns,
- For each treatment carried out, penetration depth, penetration rate, withdrawal rate, probe location,
- Volume of added backfill, backfill gradation, ammeter or hydraulic pressure, Peak, and operating vibrator-frequency.
Trend charts shall also be prepared and presented to the Engineer together with daily reports/records.
a) General
Underpinning, as directed by the Engineer, shall be undertaken as specified or instructed in the Contract Documentation. Underpinning support
may be provided by:
- Provision of temporary support to an existing structure,
- Removing existing footings and replacement thereof with new footings of greater bearing capacity, followed by removal of the temporary
support,
- Excavation beneath sections of existing foundations; constructing new footings of greater bearing capacity and ensuring load transfer to new
footings, with or without preloading of the new construction,
- Excavation under existing foundations, jacking in piles and ensuring load transfer to new piles, with or without preloading,
- Installing piles alongside existing foundations and casting new sections of footings keyed into existing foundations,
- Constructing new foundations adjacent to existing, with or without piles, and transferring load to these foundations by means of additional
columns or similar structural members or other unification measures.
- Installing piles through existing foundations and keying pile heads into existing foundation,
- Drilling small diameter holes (150–250 mm in diameter) through existing foundations and constructing micropiles beneath these foundations,
- Drilling small diameter holes (approx. 250 mm diameter) through existing foundations and installing jet grouted columns beneath existing
foundations,
- Drilling micro-holes (less than 30 mm diameter) through existing foundations and pumping under high pressures quick setting resins; silica’s
or other chemicals, or,
- Jet grouting or Compaction grouting through existing foundations as detailed in these specifications.
b) Process
Underpinning methods shall be specified in Contract Documentation and relevant specifications in various sections of this document shall be
applicable unless otherwise indicated.
c) Monitoring and Records
Monitoring and logging of all excavation, demolition, foundation compaction, reinforced concrete construction (all facets), drilling, piling and all
other activities carried out in executing underpinning shall be carried out by the Contractor. These shall include:
- Daily records of all underpinning activities,
- Positions,
- Depths of treatment,
- Start and stop times,
- Details of all stoppages, breakdowns and volume of grout injected at each position,
- Results of process control tests on materials,
- Details of any works not completed due to mechanical breakdowns, inadequacy of materials, grout, air or water supply or any other reason
and proposed remedy/remedies

The following data on each pile installed shall be recorded in a form prescribed by the Engineer:
- Effort used for driving pile and resistance to penetration at founding level,
- Description of subsurface material,
- Presence of ground water and quality of material at pile tip founding,
- Quality of materials used in construction or manufacture of pile,
- Quality of permanent casing used,
- Method of placing and compacting concrete as well as volume in cast in situ piles,
- Method of founding of piles e.g. bulbous bases, rock sockets, etc, and their dimensions
- Maximum working load of pile,
- Length of pile and accuracy of installation in respect of position and inclination,
- Nominal dimensions and type of pile,
- Length and details of any temporary and permanent casings used.
Records shall be submitted to the Engineer before noon the following working day.

a) General
(i) Method statements
The Contractor shall provide method statements for installation and operation of monitoring instruments specified in the Contract
Documentation two weeks prior to programmed installation. These statements shall cover all requirements given in these
specifications plus those included in the Contract Documentation.
(ii) Labelling and marking
All instruments shall be labelled with their reference number at locations where readings are taken as specified in the Contract
Documentation. Positions of all cabling and tubing shall also be indicated and methods/means approved by the Engineer to avoid
damage by later borehole drilling and/or drain installations.
(iii) Protection
The Contractor shall take all necessary precautions to protect installed instruments and shall maintain them in good working order
after installation. All instruments above ground shall be protected from vehicular damage by visible barriers for a distance of 750 mm
around each instrument. Heavy equipment shall not approach within 1,5 m from such instrument.
(iv) Frequencies
Frequency of measurements for each instrument shall be as specified in the Contract Documentation. Such intervals shall be adjusted
by the Engineer according to progress and time lapse.
(v) Readings
Readings and plots of recorded readings from installed instrumentation at specified intervals shall be provided to the Engineer on
each occasion. The format shall be approved by the Engineer at least two weeks before readings commence.
b) Settlement monitoring
(i) Settlement monitoring by survey methods
Unless otherwise specified, a stable benchmark shall be provided by the Engineer from which settlement shall be measured via
survey. The positions shall be indicated on the drawings. Where the Contractor is required to provide such he shall agree suitable
locations with the Engineer and arrange for the construction of the benchmark and survey thereof by a registered land surveyor. No
separate payment will be made for such work and the costs thereof shall be deemed to be included in his rates for establishment.
The Contractor shall install rod settlement gauges at locations specified by the Engineer as work proceeds. Base plates and first rod
lengths shall be placed before significant filling is commenced and extension lengths installed as filling proceeds. Where settlement
rods are damaged or not extended timeously, the Contractor shall cease works in the vicinity of gauges until remedial works are
carried out. The Contractor shall be liable for any delay in programme or for additional works necessitated thereby. Where any
settlement rod is irreparably damaged the Engineer shall assess the settlements recorded for measurement purposes and this action
shall be accepted by the Contractor.
Settlement gauges shall be monitored by precise levelling, accurate to ± 1,0 mm with levels taken at top of rod and fill adjacent to the
rod. When rods are extended, levels shall be taken before and after adding extensions.
Readings to be taken shall be as specified in the Contract Documentation and shall include:
- Displacement from survey point (as specified),
- Survey station coordinates and reduced level,
- Reduced level of rod gauge,
- Original ground level at gauge,
- Reduced level of ground at gauge,
- Record of fill placed,
- Thickness of fill placed,
- Settlement of plate relative to base-and previous readings.
(ii) Settlement monitoring with magnetic extensometers
Magnetic extensometers provide a means of measuring settlement or heave at a point or at a series of points beneath the surface.
Extendable access tubes are installed in predrilled holes. A datum ring magnet is installed some 2,0 m from lower end of tube. Spider
magnets temporarily held in place along the tube are used within the subsoil. Plate magnets within the fill can be placed during

construction. Once in position the spider magnets are released. The hole is backfilled with a bentonite: cement mix of strength
equivalent to the surrounding material.
Readout devices shall consist of a nickel-plated brass probe containing a reed switch encapsulated in silicone rubber. The probe shall
be connected via a nylon coated steel tape to a reel buzzer. All instruments and ancillary equipment shall be approved by the Engineer
before being used.
Combined inclinometers and magnetic extensometers, which provide means for measuring both vertical settlement and horizontal
displacement at a series of points below ground surface, may be considered by the Engineer.
- Reduced level of top of access extensometers,
- Reduced level of ground adjacent to access tube,
- Distance to each magnet from top of tube,
- Reduced level of each magnet,
- Settlement of each magnet relative to base readings.
c) Slope stability monitoring
(i) Inclinometers.
The Contractor shall install inclinometer monitoring systems at specified locations as indicated on the drawings. The tubing shall be
fitted with a watertight end cap and in installing the tubing. Joins shall be secured with rivets and coated in sealing mastic before being
wrapped in sealing tape. The orientation required shall be ascertained prior to installation and shall be maintained at all times. Where
the tubing is located in compressible materials it shall be coated with approved grease. The annulus between the tubing and the hole
walls shall be backfilled with a bentonite/cement grout as specified in the Contract Documentation. Prior to taking any readings, the
level of the top of inclinometer tubing shall be recorded. The inclinometer torpedo is lowered to the base of the tubing and slowly
raised, pausing to take readings every 0,5 m until the torpedo reaches the surface/top. The procedure is repeated centering the
torpedo in the keyways 900 to the first set. Processing of data on the digital readouts shall be done according to the manufacturer’s
instructions and supplied software.
- Level of tube top,
- Ground level adjacent to tube-top,
- Horizontal movements of top of tube from survey,
- List of deflections and graph showing horizontal movements relative to base readings,
- Fill height.
d) Stability monitoring
(i) Pore water pressure monitoring - Standpipe piezometers
Where specified, standpipe piezometers, as detailed in the Contract Documentation shall be installed at the locations shown on the
drawings or as may be instructed by the Engineer. The piezometers are installed in predrilled boreholes. The positioning of the porous
element shall be as specified or instructed by the Engineer and filter sand shall be placed in the annulus between the piezometer tube
and borehole sidewalls to required position of the element.
The elevation of the porous element shall be recorded. Further filling with filter sand shall be carried out to generate the required
cover. The top level of the sand shall be determined. Seals comprising bentonite pellets shall be placed above and, if necessary,
below the sand filter. The remainder of the hole shall be filled with bentonite cement grout.
Unless otherwise specified, the piezometer shall exit within a 1,5 m, 100 mm Ø standpipe set in a 400x400x300 mm concrete block,
cast 100 mm proud of the ground surface.
- Date,
- Level of tube top,
- Ground level,
- Depth of water from top of tube,
- Water pressure,
- Change in water head
(ii) Pore water pressure monitoring - Pneumatic piezometers
The Contractor shall install Pneumatic piezometers sat depths and locations as specified. The arrangements of the equipment shall
be as shown on the drawings.
Prior to installation the piezometer tip and flow and return tubing shall be pressure tested as specified in the Contract Documentation
to check for leaks. The borehole in which the piezometer is to be installed shall be terminated 0,3 m above the required tip position.
The piezometer with connected tubing is then pushed into the base of the borehole to the required depth and the borehole is sealed
with bentonite pellets and bentonite: cement grout as specified. The cables and tubes shall be laid in trenches backfilled with sand
from the hole position to the terminal panel and backfilled with sand, all as shown on the drawings. The colour coding ensures that
the flow and return tubes are connected correctly Readings shall be taken and stored on the readout device.
- Date,
- Level of installed piezometer head,
- Water pressure,
- Water head,
- Change in water head (m)

(iii) Soil pressures/loads
Load cells shall be installed as per the manufacturer’s instructions at positions specified and as may be instructed by the Engineer.
The tubing and/or cabling connecting the load cells shall be placed in trenches and backfilled with sand. The positioning and protection
of the readout units shall be agreed with the Engineer.
- Date of reading,
- As installed level of load cell,
- Pressure/ loading,
- Changes in pressure/ loading (kPa)
(iv) Installation Reports
The Contractor shall submit an installation report once installation of all instruments is completed which shall include:
- All base readings,
- Plans indicating locations, elevations and other specified data,
- Photographs of all instruments and recording units.
e) Monitoring and records
The Contractor shall submit reports at intervals specified in a format approved by the Engineer at least two weeks prior to initial-report submission.
Each report shall include a description of works in operation, observations and data tabulations and/or plots from date of installation to present for
all installed instruments, as specified in the Contract Documentation.

This section covers the supply, installation and testing of basal reinforcement of embankments. The construction of basal reinforcement shall be
carried out in accordance with SANS 54475. In particular the following shall be adhered to:
a) Transport and storage

Basal reinforcing elements shall be transported and stored as per the manufacturer’s recommendations and as may be specified in the Contract
Documentation. Damaged materials shall be removed from site and replaced with new materials.
b) Surface preparation
Prior to placement of the specified geosynthetic installation, an area 1m wider than the structure to be supported shall be prepared by ripping the
in situ material to 200 mm depth and re-compacting to greater than 88 % Maximum Dry Density (MDD) as per SANS 3001 at a moisture content
of 0 to plus 2 % of the optimum. Unless otherwise specified compaction shall be carried out using a vibrating padfoot roller of at least 300kN
centrifugal force, operating in high amplitude mode at a speed not exceeding 0,5 m/sec. Unless otherwise specified or ordered by the Engineer
at least 15 passes with a 300mm overlap shall be carried out. Payment for this work shall be made under item C5.1.5.2 of Chapter 5.
c) Placement of geosynthetic
The geosynthetic shall be placed over the area and tensioned so that it is free of kinks and folds. Subsequent layers of geosynthetic shall be
overlapped in the length by 500 mm and the overlap shall be filled with overlap sand to a minimum thickness of 20 mm. Where two rolls are joined
end to end, the overlap distance shall be greater than 2,0 m and shall also filled with overlap sand to a minimum thickness of 20 mm. The ends
of the geosynthetic shall exit the undercut by a minimum of 1,0 m.
d) Placement of protection layer
A 125 mm loose layer of G8 or better quality material shall be placed over the geosynthetic to act as a protection layer by end -tipping so that
construction traffic does not travel directly on the geosynthetic. Further fill construction can be carried out by conventional means unless otherwise
specified.
A12.3.8 WORKMANSHIP
A12.3.8.1 General
The Engineer will conduct routine inspections and tests to determine whether the workmanship provided complies with the requirements of this
section. The Engineer shall assess compliance with the requirements specified in the Contract Documentation.
The Contractor, however, shall carry out all necessary process control measures required in terms of Clause A1.2.8.1 in Chapter 1 as indicated
in the approved Quality Assurance Plan and as may be specified in the Contract Documentation.

The following approved quality control measures shall be carried out as may be applicable and as may be specified in the Contract Documentation:
a) Tests on completed works
- UCS testing on extracted cores,
- Water acceptance pressure tests (lugeon tests)
Any other tests as may be prescribed in the Contract Documentation.

b) Tests on fresh cementitious grout
(i) Consistency
Viscosity consistency of each batch of cementitious grouting shall be tested with the flow cone (Clause A20.1.5.6 b)(iv) of Chapter
20).
(ii) Density
The Engineer may require that density of each batch of cementitious grout be tested with an approved grout hydrometer to measure
specific gravity (or relative density) of the cementitious grout. Ranges in values shall be determined as works proceed and shall be
monitored for fluctuations.
(iii) Strength Testing
During batching of cementitious grout, 100 mm cubes shall be made, cured and tested in accordance with SANS 3001-CO11at
frequencies specified in Contract Documentation. Three cubes are required per test.
Consistency and density tests on freshly batched grout mixes are considered as process control by the Contractor and no separate
payment will be made for ongoing testing of grout using these methods.
c) Acceptance Criteria
Grouting acceptance or rejection shall be based on the Contractor’s ability to achieve specified criteria which may include:
- Specified permeability,
- Grout consistency,
- 28 day characteristic strength of grout cubes,
- UCS results on cores.
The characteristic strength of the grout shall be as specified in the Contract Documentation. Results of strength tests on grout will be assessed
for acceptance if the average strength exceeds the specified strengths with no single test less than 95% of the specified strength. If these criteria
are not obtained, the Engineer may instruct that additional grouting shall be undertaken until compliance with is achieved.

The following approved quality control measures shall be carried out as may be applicable and as may be specified in Contract Documentation.
a) Soilcrete columns
- UCS Testing of 100 mm drilled cores from constructed soilcrete columns,
- Coring down the centre of constructed columns and UCS testing of selected core lengths,
- Compressive strength tests on 100 mm cubes made from jetting spoil return,
- Any other tests as may be prescribed in the Contract Documentation
b) Cementitious grout
(i) Consistency:
Consistency of each batch of cementitious grouting shall be tested for consistency with the Flow Cone (Clause A20.1.5.6b)(iv) of
Chapter 20) and an approved grout hydrometer to measure specific gravity (or relative density) of cementitious grout and drilling
fluids. Ranges in values shall be determined as works proceed and any significant variation from moving average shall immediately
be investigated and brought to attention of the Engineer.
(ii) Strength testing - grout cubes
During batching of cementitious grout, 100 mm cubes shall be made, cured and tested in accordance with SANS 3001-CO11at
frequencies specified in the Contract Documentation. Three cubes are required per test.
(iii) Strength testing - return grout cubes
These shall be made at a rate of one cube for each column as an indication of soilcrete mix strength in the column.
(iv) Evaluation of exposed soilcrete columns
The Engineer shall direct which columns are to be exposed for uniformity and diameter measurements and further testing. Such
testing may comprise coring 100 mm diameter cores from top or exposed sides of exposed columns.
Where specified, full length coring of completed columns shall be carried out, utilising appropriate, approved equipment, bits and core
barrels of size indicated. Testing of selected core lengths required to prove strength of constructed soilcrete columns.
Where soil cement structures such as walls of various types (secant wall, contiguous walls, etc) are required for water control
purposes, borehole permeability tests may be specified in the Contract Documentation.
c) Acceptance Criteria
The characteristic strength of the grout shall be as specified in the Contract Documentation. Results of strength tests on grout will be assessed
for acceptance if the average strength exceeds the specified strengths with no single test less than 95 % of the specified strength.

a) General
The following approved quality control measures shall be carried out as may be applicable and as may be specified in the Contract Documentation.
b) Tests on completed works
Degree of compaction of soil achieved between adjacent grout holes will be measured by way of either:
- CPT, CPTu, Piezocone, or

- SPT, DPSH and DPL, or
- PMT, or
- CSW tests,
- PLT.
c) Tests on Grout
(i) Slump
Workability of each batch shall be tested with a slump cone.
(ii) Strength
During the course of batching, 100 mm cubes shall be made, cured and tested in accordance with SANS 3001-CO11.
Slump and strength tests are considered as process control by the Contractor and no separate payment will be made for these tests.
The characteristic strength of the grout shall be as specified in the Contract Documentation. Results of strength tests on grout will be
assessed for acceptance if the average strength exceeds the specified strengths with no single test less than 95 % of the specified
strength.
d) Acceptance Criteria
Acceptance or rejection shall be based on the Contractor’s ability to achieve project specification criteria, which may include: slump and strength
requirements, SPT, DPSH, DPL, Piezocone, CPT, CPTu, PMT, CSW and PLT.
If these criteria are not obtained, the Engineer may instruct that additional grouting be undertaken until compliance is achieved. If non-compliance
is attributable to the Contractor, no payment shall be made for additional work.
A12.3.8.5 Dynamic and rapid impact compaction

a) General
The following approved quality control measures shall be carried out as may be applicable and as may be specified in the Contract Documentation
(i) Condition survey
The Contractor shall carry out a condition survey of the site, and any surrounding structures which could be affected by vibrations
resultant from dynamic compaction process before any earthworks or dynamic or rapid impact compaction is performed. This survey
will take the form of a checklist and electronic photographic record drawn up by the Contractor and approved by the Engineer. Checks
shall subsequently be conducted on a weekly basis until completion of stone columns/in situ imprints and vibratory rolling and a final
evaluation 2 weeks thereafter. The cost of carrying out this survey is deemed to be to be included in the Contractor’s rates and no
separate payment will be made for this work.
(ii) Vibration monitoring
Continuous vibration monitoring during the duration of the contract shall be carried out. The Engineer will direct placement of
equipment. A back-up instrument shall be provided on site. These instruments shall be capable of measuring vibration response in
three mutually perpendicular directions, vertically, radially and transversally (the latter two in the horizontal direction), to an accuracy
of 0,01 g. The Contractor shall process or have results processed by an approved organisation/person to provide the Engineer with
acceleration and peak particle velocity responses both in graphic and numeric format. The cost of continuous monitoring of vibrations
resultant from dynamic compaction process is deemed to be included in the Contractor’s rates and no separate payment will be made
for this work.
A Peak Particle Velocity (PPV) of less than 25 mm/sec shall apply, unless otherwise specified in the Contract Documentation.
b) Testing
(i) Plate load tests
Plate load tests shall be conducted on top of installed stone columns or compacted points backfilled as specified or as directed by the
Engineer.
Unless otherwise specified in the Contract Documentation, a suitably stiff plate of diameter greater than 600 mm, approved by the
Engineer, shall be used with the reaction provided by the ram compaction excavator under the following conditions:
- Maximum plate stress of 500kPa,
- An unload/reload cycle at 50 % of maximum stress,
- A minimum deformation modulus of the stone column (derived from the unload/reload cycle of the plate load test) of E=50MPa.
The analysis method of Wrench (1984/85) shall be used in derivation of deformation modulus.
(ii) Continuous Surface Wave tests (CSW)
As directed by the Engineer or as specified in the Contract Documentation, CSW testing shall be conducted to depths as indicated in
the Contract Documentation after DC and RIC. Tests shall be carried out after finishing off of the treated area as specified (backfilling
of craters or earthworks and rolling by vibrating padfoot compaction).
To ensure efficacy of compaction, minimum Vs-value recorded in CSW tests at depths greater than 0,5 m shall be greater than>160
m/sec.
(iii) Dynamic Cone Penetrometer tests (DCP).
If CSW testing is not possible, the top 2,0 m of compaction shall be measured immediately after final compaction using a 2,0 m DCP.
No single point in the 2,0 m deep profile shall indicate an in-situ CBR value of less than 22 (approximately 10 mm/blow).
Any positions outside the above range will be deemed to represent non-compliance and no payment will be made for that portion of
the work.

(iv) DPSH
The DPSH can be used to obtain an empirical indication of the consistency of the soil profile providing a comparison between
conditions prior to- and after treatment.
c) Construction limitations
Surrounding structures and services, both above- and underground could be affected by vibrations resultant from DC/RIC processes. Measures
shall be taken by the Contractor on an ongoing basis to limit within tolerable levels, the extent of vibrations resultant from the works in order to
prevent damage to such structures and/or services. See Clause A12.3.8.4.

a) General
On completion of vibration compaction, overall stiffness at various positions shall be checked via CSW testing. If this is not feasible CPT, DPSH,
PMT or PLT as directed by the Engineer will be used to ensure target compaction is achieved.
Requirements under the various methods used for underpinning of structures as specified in relevant Chapters and Sections of these specifications
shall apply.

The Contractor shall test all instrumentation before installing in/below embankment fills to be constructed. Instruments shall further be tested
immediately after installation and functioning of each shall be demonstrated to the Engineer including the recording of measured values using
appropriate readout devices. As part of commissioning, three sets of base readings shall be taken. The Contractor shall rectify any defective
instrument before proceeding with works post installation.

The geosynthetic supplier shall submit results of the long term strength the determinations including the stress/strain and long term creep
characteristics of the geosynthetics proposed for use/supplied for soil reinforcement in terms of the guidelines in SATR20432.

B12.3 GROUND IMPROVEMENT
CONTENTS
B12.3.1 SCOPE
B12.3.2 DEFINITIONS
B12.3.3 GENERAL
B12.3.5 MATERIALS
B12.3.8 WORKMANSHIP
B12.3.1 SCOPE
B12.3.2 DEFINITIONS
B12.3.3 GENERAL

B12.3.5 MATERIALS


B12.3.8 WORKMANSHIP

C12.3 GROUND IMPROVEMENT
(i) Preamble
pay items.
C12.3.1 Site Establishment
C12.3.1.1 Geotechnical Grouting lump sum
C12.3.1.2 Jet Grouting lump sum
C12.3.1.3 Compaction Grouting lump sum
C12.3.1.4 Dynamic compaction lump sum
C12.3.1.5 Rapid impact compaction lump sum
C12.3.1.6 Vibration compaction lump sum
C12.3.1.7 Underpinning lump sum

C12.3.1.8 Preloading lump sum
C12.3.1.9 Basal reinforcement lump sum
The tendered lump sum for site establishment for items C12.3.1.1 to C12.3.1.9 above shall include full compensation for establishing all necessary
plant, equipment and services on site to carry out the works as specified including all work in preparing the works area for construction activities
and subsequent removal from site of all such plant and equipment including all temporary works such as access roads, staging, platforms and
such like. The tendered rate for preload monitoring shall include for the establishing on site of all the necessary equipment and material as
specified required for the installation of the specified monitoring instruments and for the removal thereof on completion of the works. The provision
of boreholes in which instruments are to be installed, and the supply of the specified instruments and accessories as may be required, shall be
paid for separately.
The work will be paid for by way of a lump sum, 50 % of which shall be payable when all major necessary equipment is on site, trials (if any) are
completed and the first production work started. The second instalment of 25 % is payable after half the specified work is complete. The final
instalment shall be payable after all work is complete, all equipment has been removed and the site restored as specified in the Contract
Documentation.
C12.3.2 Moving to and setting up equipment at each position for:
C12.3.2.1 Geotechnical Grouting number (No)
C12.3.2.2 Jet Grouting number (No)
C12.3.2.3 Compaction Grouting number (No)
C12.3.2.4 Dynamic compaction number (No)
C12.3.2.5 Rapid impact compaction number (No)
C12.3.2.6 Vibration compaction number (No)
C12.3.2.7 Underpinning number (No)
C12.3.2.8 Preloading number (No)
C12.3.2.9 Basal treatment number (No)
The unit of measurement shall be the number of positions to which equipment is moved and set up in position to execute the works as described
in the Contract Documentation. The quantity measured shall be the number of set ups at designated works positions inclusive of approved trial
works positions as well as any additional positions as may be instructed by the Engineer.
The tendered rates shall include full compensation for all costs involved in moving to and setting up required equipment at each works position.
Multiple setups at the same hole shall only be measured and paid for once. Tendered rates shall also include all costs in setting-up equipment
and subsequent decommissioning thereof
C12.3.3 Setting out of works at treatment positions number (No)
The unit of measurement shall be the number of positions set out by a registered surveyor as per Contract Documentation or as instructed by the
Engineer. Payment will not be made for re-setting out of treatment positions lost for whatever reason.
The tendered rate shall include for all labour, plant, equipment, materials and all incidentals required.
C12.3.4 Grouting (Cement)
C12.3.4.1 Geotechnical grouting kilogram (kg)
C12.3.4.2 Jet grouting kilogram (kg)
C12.3.4.3 Compaction grouting kilogram (kg)
The unit of measurement shall be kilograms (kg) of cement actually utilised for grouting as specified and approved by the Engineer.
The tendered rates shall include for all labour, plant, equipment, materials, delivery, storing, mixing, pumping, injection and all incidentals required.
No payment will be made for any wastage or for rejected batches. Only verified quantities will be accepted for measurement and payment.
The rate shall include quality control measures, testing of materials, monitoring and supervision of the works, daily records of all items specified

C12.3.5 Grouting (Fillers and Additives)
C12.3.5.1 Sand kilogram (kg)
C12.3.5.2 Bentonite kilogram (kg)
C12.3.5.3 Other fillers (specify) kilogram (kg)
The unit of measurement shall be the kilograms (kg) of filler/additive actually utilised for grouting as specified and approved by the Engineer.
Tendered rates shall include for all labour, plant, equipment, materials, delivery, storing, mixing, pumping, injection and all incidentals required.
No payment will be made for any wastage or for rejected batches. Only verified quantities will be accepted for measurement and payment.
The rate shall include quality control measures, testing of materials, monitoring and supervision of the works, daily records of all items specified
C12.3.6 Drilling of holes for geotechnical /compaction grouting (diameter and inclination metre (m)
indicated)
The unit of measurement shall be the metre of hole actually drilled and re-drilled. No differentiation will be made for different drilling methods (e.g.
rotary, percussion, rotary percussion or vibratory drilling), unless otherwise specified.
The tendered rate shall include full compensation for drilling holes of appropriate diameter including, drilling aids, drilling materials and disposal
of all waste products on completion thereof. Casings/sleeves shall be measured and paid for separately.
C12.3.7 Extra over for drilling through reinforced concrete metre (m)
The unit of measurement shall be the metre of drilling through reinforced concrete.
The tendered rate shall include for all labour, plant, equipment and materials to carry out the drilling as required.
C12.3.8 Drilling holes for jet grouting to specified depths (depth ranges and inclinations to be metre (m)
specified)
The unit of measurement shall be the metre of hole drilled of specified diameter and as specified in all materials.
The tendered rate for forming holes shall include full compensation for drilling and disposing of surplus material resulting from the hole being
formed. No differentiation will be made for different drilling methods (e.g. rotary, percussion, rotary percussion or vibratory drilling) unless otherwise
specified.
C12.3.9 Installation of casing (diameter and inclination indicated) metre (m)
The unit of measurement shall be the metre of temporary casing installed.

The tendered rate shall include full compensation for supplying the indicated diameter casing, installation thereof and for subsequent removal and
shall include for all labour, plant and equipment required for this. No extra time will be granted for installation and removal of temporary casing.
C12.3.10 Installation of standpipes for geotechnical grouting number (No)
The unit of measurement shall be the number of standpipes installed.

The tendered rate shall include full compensation for supply, installation, securing in position of approved standpipes complete with suitable
couplings for the attachment of grout hoses.
C12.3.11 Injection Grouting (type indicated) cubic metre (m3)
The unit of measurement shall be the cubic metre of grout actually injected into the fissure/cavity/void/material.
The tendered rate shall include full compensation for the mixing, storing, pumping and placement of the approved grout and shall include for all
labour, materials (other than for which provision for payment has been made in the Contract Documentation), quality control measures, the testing
of materials, monitoring and supervision of the works the daily recording of results, injection parameters, production and other record keeping and
reporting all as specified in the Contract Documentation.

C12.3.12 Extra-over items 12.3.4 and 12.3.5 for stage grouting (specify up-or downstage) number (No)
The unit of measurement shall be the number stages grouted to required pressures.
The tendered rate shall include full compensation for all additional costs of managing each stage.
C12.3.13 Extra-over items 12.3.4 and 12.3.5 for jet grouting of widened sections or mushroom number (No)
heads (position and width to be specified)
The unit of measurement shall be the number of widened sections or mushroom heads constructed as specified.
The tendered rate shall include full compensation for all additional cost for this operation.
C12.3.14 Exposing test jet grouted columns number (No)
The unit of measurement shall be the number of columns exposed for inspection, measurement and testing.
The tendered rate shall include for all plant, excavating the material around the column and trimming of the column as well as backfilling of
excavations with suitable material in 150mm layers compacted to required density.
C12.3.15 Coring of jet grouted columns
C12.3.15.1 Setting up over completed jet grouted columns number (No)
C12.3.15.2 Drilling and core recovery (size indicated) metre (m)
C12.3.15.3 Provision of core boxes number (No)
The unit of measurement shall be per set up over a completed, cured column as instructed by the Engineer.
The unit of measurement for drilling and recovery of core samples using appropriate methods and equipment of size indicated.
cubic metre-
C12.3.16 Removal of jetting and drilling spoil
kilometre (m3-km)
The unit of measurement shall be the cubic metre of spoil hauled over the distance covered.
The tendered rate shall include for the loading, transport and all other costs in hauling the spoil material to the approved spoil site.
C12.3.17 Performing dynamic compaction over (specify distance) utilising a (indicate mass) tonne
pounder
C12.3.17.1 Primary prints blows
C12.3.17.2 Secondary prints blows
C12.3.17.3 Ironing prints blows
The unit of measurement will be the number of blows imparted at a compaction point. Differentiation is made between primary phase, secondary
phase and ironing phase works.
The tendered rate will include full compensation for carrying out the specified dynamic compaction in full compliance with the specifications at
designated compaction points including the ongoing vibration measurement and monitoring as specified and for the placement of dumprock during
the construction of stone columns. Separate payment shall be made for the procuring of dump rock.
C12.3.18 Variation in number of blows
C12.3.18.1 Primary prints blows
C12.3.18.2 Secondary prints blows
C12.3.18.3 Ironing prints blows
The unit of measurement in respect of increase or decrease in the number of blows imparted in the execution of dynamic compaction at designated
compaction points as instructed or approved by the Engineer.
Differentiation is made between primary phase, secondary phase and ironing phase works.
Payment for variations shall be made as specified in Clause C1.1.4

C12.3.19 Importing G7quality material from approved sources cubic metre (m3)
The unit of measure shall be the cubic metre of imported G7 quality material.
The tendered rate shall include full compensation for procuring, stockpiling, watering to compaction moisture content for processing as backfill in
craters formed by dynamic compaction or for the construction of capping layer or for general layerworks, levelling and finishing of compacted
areas. The quantity shall be taken as 70 % of the volume transported to site as measured in trucks. Only full, struck-off loads arriving on site shall
be paid for.
C12.3.20 Importing dump rock for forming stone columns by dynamic compaction from cubic metre (m3)
approved sources
The unit of measure shall be the cubic metre of dump rock as specified for forming of stone columns by dynamic compaction.
The tendered rate shall include full compensation for the procuring, stockpiling and placement during the construction process. The quantity shall
be taken as 70 % of the volume transported to site as measured in trucks.
C12.3.21 Importing crushed rock for vibratory replacement from approved sources cubic metre (m3)
The unit of measure shall be the cubic metre of imported G7 crushed rock for vibratory replacement as specified from approved sources.
The tendered rate shall include full compensation for the procuring, stockpiling, and for the placement in craters formed by vibrocompaction/
vibroflotation.
The quantity shall be taken as 70 % of the volume transported to site as measured in trucks. Only full, struck-off loads arriving on site shall be
paid for.
C12.3.22 Water acceptance testing (permeability tests as specified) number (No)
The unit of measurement shall be the number of tests carried out as instructed by the Engineer in accordance with the Contract Documentation.
The tendered rate shall include full compensation for establishing approved equipment on site and all costs incurred in carrying out the tests by
competent persons plus record keeping and reporting.
C12.3.23 Plate load tests number (No)
The unit of measurement shall be the number of plate load tests carried out as specified on the instruction of the Engineer.
The tendered rate shall include full compensation for the provision of the testing equipment on site for the duration of the works, for the carrying
out of the tests by competent persons and for the provision of the test data as specified in Contract Documentation.
C12.3.24 Establishment on site for
C12.3.24.1 DCP testing (depth indicated) lump sum (LS)
C12.3.24.2 CPT testing (depth indicated) lump sum (LS)
C12.3.24.3 DPSH testing (depth indicated) lump sum (LS)
The tendered lump sum for dynamic compaction shall include full compensation for the establishment and removal from site of all the plant and
equipment required to carry out the testing as specified inclusive of all preparatory work that may be required and all operations for which the cost
does not vary with actual amount of testing carried out.
The lump sum rate shall include full compensation for the provision of all the resources inclusive of water and electrical power for carrying out the
tests as specified.
This work will be paid for by way of a lump sum, 50 % of which will become payable when all the equipment is on site, trials (if any) are completed
and the first tests successfully conducted. The second instalment of 25 % of the lump sum will be payable after half the total number of tests are
completed and the final instalment of 25 % after all the testing work is complete, the results accepted by the Engineer and the equipment has
been removed from site.

C12.3.25 DCP, CPT and DPSH testing
C12.3.25.1 DCP testing (depth indicated) number (No)
C12.3.25.2 CPT testing (depth indicated) number (No)
C12.3.25.3 DPSH testing (depth indicated) number (No)
The unit of measurement shall be the number of tests carried out as specified on the instruction of the Engineer.
The tendered rate shall include full compensation for the setting up of the equipment at each designated testing point, the execution of the tests
by competent persons as specified as well as the provision other the test results in an approved format within 24 hours of testing.
C12.3.26 Continuous surface wave testing (CSW) number (No)
The unit of measurement shall be the number of tests carried out on the instruction of the Engineer.
The tendered rate shall include full compensation for the provision of the testing equipment on site for the carrying out of the tests by competent
persons and for the provision of the test data, all as specified.
C12.3.27 Monitoring of instruments and earthworks by survey month
The unit of measurement shall be the period over which the Contractor shall have in his employ a suitably-qualified and experienced surveyor
equipped with all the necessary survey equipment to carry out the monitoring as specified.
The tendered rate shall include for all labour, materials, calibrations and other items required to complete the works as specified.
C12.3.28 Supply and install rod settlement gauges number (No)
The unit of measurement shall be the number of rod settlement gauges supplied and installed.
The tendered rate shall include for the supply and installation of the base plates and extension rods (number indicated) as specified, the marking
and protection thereof. The tendered rate shall also include for all the labour, materials, periodic installation of extension rods required as well as
for the recording and reporting of settlement results.
C12.3.29 Supply and install standpipe piezometers number (No)
The unit of measurement shall be number of standpipe piezometers supplied and installed.
The tendered rate shall include for supply and installation of standpipe piezometers as specified as well as the labelling, survey and the protection
thereof. The tendered rate shall also include for all labour, materials, reading equipment and all incidentals required for the measurement of water
levels, the recording and for the reporting of the results as specified, Boreholes in which piezometers are installed shall be measured separately.
C12.3.30 Supply and install pneumatic piezometers (lengths indicated) number (No)
The unit of measurement shall be number of pneumatic piezometers supplied and installed.
The tendered rate shall include for supply and installation of pneumatic piezometers as specified, labelling, survey and protection thereof. The
tendered rate shall also include for all labour, materials, tubing, cabling, couplings, manifolds, readout and recording, unit cabinets and incidentals
required for measurement of water levels, recording, processing and for reporting of results as specified. Boreholes in which piezometers are
installed shall be measured separately.
C12.3.31 Supply and install inclinometer monitoring systems (lengths indicated) metre (m)
The unit of measurement shall be metre of inclinometer tubing installed.

The tendered rate shall include for the supply and installation of the tubing, the labelling and survey and the protection thereof as specified
The tendered rate shall also include for all the labour, materials, tubing, cabling, inclinometer torpedo and readout unit and all incidentals required
for the measurement of displacement of the installed tubing, processing and for the reporting of the results as specified.
Boreholes in which inclinometers piezometers are installed shall be measured separately.
C12.3.32 Supply and install pressure measuring loadcells (type and make specified) number (No)
The unit of measurement shall be the number of loadcells of the specified type installed in the earthworks during construction.

The tendered rate shall also include for all the labour, materials, tubing, cabling, and loadcells, readout unit and all incidentals required for the
measurement of earth pressures during construction and for the processing and reporting of the results as specified.
C12.3.33 Supply and install geosynthetic for basal reinforcements square metre (m2)
The unit of measurement shall be the square metre (m2) of geosynthetic placed as specified.
The tendered rate shall include for the procurement, transport, storage and placement of the specified geosynthetic, measured in place inclusive
of all labour, incidentals and materials.
C12.3.34 Supply and placement of 125 mm protection layer cubic metre (m3)
The unit of measurement shall be the cubic metre (m 3) of approved material.

The tendered rate shall include for the supply, transport and placement as specified, of approved material inclusive of all labour, plant and
incidentals required therefore.

D12.3 GROUND IMPROVEMENT
The Contractor shall provide detailed specifications and certificates from independent reputable agencies for all proprietary casing/sleeves and
materials proposed for use. These shall demonstrate conformance with the performance requirements stipulated in the Contract Documentation.
CONTENTS
D12.3.1 SCOPE
D12.3.2 GENERAL
D12.3.1 SCOPE
D12.3.2 GENERAL

- Materials and Materials Design as per Clause A12.3.2
- Materials as per Clause A12.3 5,
- Execution of the Works as per A12.3.7








12.4 LATERAL SUPPORT
CONTENTS
A12.4.1 SCOPE
A12.4.2 DEFINITIONS
A12.4.3 GENERAL
A12.4.5 MATERIALS
A12.4.8 WORKMANSHIP

A12.4 LATERAL SUPPORT

A12.4.1 SCOPE
This Section covers some of the various techniques employed to provide lateral support including Sheet Piling and Diaphragm Walls where this
forms part of the permanent works and provision is made for the payment thereof in the Contract Documentation.
Other commonly used methods such as secant/contiguous piling, soil nailing, rockbolting and rock doweling, shotcreting, etc are addressed
elsewhere.
A12.4.2 DEFINITIONS
Embedded wall - is a structural wall, partially or fully embedded in subsoils. Embedment may be achieved by driving the structure or elements of the
structure into the subsoils or by placement into preformed holes or trenches. The structural wall is designed either as a cantilever to provide the primary
support, or to act as a support system against which braced or tie-back forces are mobilised. Embedded walls may comprise:
- Steel sheet piles
- Precast concrete sheet piles
- Steel soldiers
- Concrete soldier piles
- Contiguous and secant pile walls
- Diaphragm walls
Sheet pile wall - is an embedded wall comprising individual steel or precast concrete sheet piles linked together and driven into the ground to provide
lateral support and/ or an impermeable barrier. Steel sheet piles are more common than precast concrete.
Steel sheet piles - are Z- and U-shaped hot rolled steel sheet pile elements (manufactured and imported from Europe or the UK).
Pile threader - is a mechanical device used to interlock sheet piles into panels for grouped installation.
Slinging Hole - is a lifting hole located near individual pile sheets approximately 32 mm in diameter usually located 150 mm from the sheet ends.
Interlock - sheet pile interlock is preformed through coupling edges allowing individual steel piles to lock onto one another thereby providing a tight
high-strength bond.
Crimping - is spot pressure indentation which permanently locks one sheet pile to another in order to increase resistance against bending, and thereby
allowing faster pile installation.
Tie rods - are anchors used in sheet piling to retain sheet pile walls to remote deadman anchorages. They may comprise stand- alone steel elements
suitable protected against corrosion or reinforced concrete beams.

Turnbuckle - a turnbuckle joins plain tie-rod ends to upset end of a tie rod.
Waler - is a horizontal beam capable of transferring load between individual anchor elements (tie-rods, props, ground anchors, etc).
Combined Sheet Pile Wall - is an embedded wall using a combination of sheet piles and king piles (box, H, tubular steel tubes, etc) to create large
bending resistance. King piles can also be used as end-bearing piles with the intermediary sheet piles acting mainly as soil-retaining and load-
transferring elements.
Guide Frame - is a frame used to enable exact placement and vertical orientation of king pile elements in combined sheet pile walls.
Driving cap - is a sheet pile capping to provide consistent energy transfer between hammer and sheet pile section thus preventing damage to top
end of pile.
Pile extractor - is used in temporary works to extract piles for re-use.
Diaphragm wall - is an embedded wall constructed using a narrow trench excavated into in situ ground and supported by an Engineered fluid (typically
bentonite slurry) until the slurry is replaced by permanent material. Permanent material generally comprises reinforced concrete, though unreinforced
walls can also be used.
Guidewall - comprises of two shallow reinforced concrete, brick –or concrete block walls constructed to ensure panel excavations are aligned within
acceptable tolerances. The internal wall is usually removed after completion of the diaphragm wall.
Stop end - is a vertical steel tube, polystyrene or precast concrete column placed at panel edges to provide, on withdrawal, a recess joint between
adjacent panels. The recess joint promotes water tightness.
Diaphragm Panel - comprises of one individual unit of the wall constructed against another (one side or two) in pre-planned rotation to final completion
of the diaphragm wall.
Pitching - means raising or lifting construction elements into a vertical position.
Panel Recess - panel recessing via stop ends is required to link individual reinforced concrete panels into a continuous watertight wall.
A12.4.3 GENERAL
The Contractor shall be required to construct trials and the testing thereof as specified herein and shall make due allowance therefore in his
programme. Allowance shall also be made for allow for the Engineer’s assessment of constructed works, procedures followed, and materials and
plant utilised and test data. Production work shall not be permitted until it is shown and accepted by the Engineer that the Contractor possesses
the necessary experience, plant and equipment to carry out the works as specified in the Contract Documentation.

of the works:

Table A12.4.3-1: Approvals Required
CLAUSE REQUIREMENTS* PERIOD/WORKS PUT ON HOLD
A12.4.4.3 Concrete mix design for Diaphragm walls 6 weeks before placement
Materials Approvals
A12.4.5.1 Sheet piling materials 2 weeks before utilisation
Construction Method Approvals
A12.4.4.2 Sheet piling method statement 2 weeks before works commenced
A12.4.4.3 Diaphragm wall method statement 2 weeks before works commenced

A12.4.5.1 Sheet pile damage remediation 2 days before commencement
A12.4.5.1 Burning or drilling of lifting holes 2 days before commencement
A12.4.3.3 Sheet piling

Sheet piling is construction of an embedded wall achieved by combining individual steel or precast concrete sheet piles linked together and driven
either to refusal or predetermined depth, into the ground to provide lateral support and/or an impermeable barrier. Each sheet pile has a pair of
clutches that allow the male of one sheet to interlock with the female of another. The resultant structural wall forms an integral part of the overall
lateral support system and is designed either as a cantilever to provide primary method of support, or to act as a support system against which
braced or tie-back forces are mobilised.
Sheet piles are mostly constructed from steel sheets imported from the United Kingdom or Europe. Precast concrete elements are generally
manufactured locally.
The commencement of the production may only commence when the Engineer has given written acceptance of designs for which the Contractor
is responsible in terms of the Contract Documentation, the Contractor’s method statements, and approval of plant and equipment.
A12.4.3.4 Diaphragm walls

Diaphragm walls are cast in situ concrete walls, generally reinforced, using under-slurry techniques. Diaphragm walls are necessary:
- In very unstable soil profiles beneath the water table where continuous support and watertight joints are required to prevent mudflows, piping
and erosion of soils
- Where time is limited and the construction of a diaphragm wall to provide support and/or water retention allows earlier subsurface excavations.
In conditions where deeper than normal cantilever support may be required, for example, where the wall acts as cantilever only, or where a
very deep initial excavation is required before the first braced or tie-back support can be installed.
Diaphragm walls require a large site area. They are not suited to small or shallow basement excavations.
Wall widths from 600 mm to 1500 mm can be formed using diaphragm walls, to depths greater than 60 m. The resultant structural wall forms an
integral part of deep lateral support and is designed either as a cantilever to provide primary support or water retention/dewatering, or to act as a
support system against which braced or tie-back forces are mobilised. Cantilever is generally effective between 4,0 and 6,0 m; bracing up to 10
m, and anchored walls to 25 m and higher.
Commencement of production shall only start when the Engineer has given written acceptance of designs for which the Contractor is responsible
for in terms of the Contract Documentation, the Contractor’s method statements, and approval of plant and equipment.

A12.4.4.1 General
The Contractor shall design the concrete and/or grout used in carrying out the works as specified. Mix designs shall be complete, be presented
on the required forms and shall be presented to the Engineer with samples of all the constituents as required at least 6 weeks prior to placement
Where design by the Contractor for any specialised/proprietary technique to be carried out is, in terms of project specification the responsibility of
the Contractor, all the aspects given below shall be taken into consideration in carrying out these obligations.
- Techniques and methods to be followed
- Material type and quality
- Site specific requirements
- Limits of areas and depths to be treated
- Concrete mix design
- Bentonite slurry mix design
- Reinforced concrete strength, panel characteristics, post-treatment properties, durability and any other deliverables as may be appropriate
- Layout of lateral support
- Sequence of installation
- Permissible limits (pressures, flow rates)
- Quantities of grout/other materials (if required) to be injected/used
- Monitoring of works
- Quality and workmanship requirements
- Measurable properties to be achieved over the life span of project
- Anti-corrosion requirements
- Environmental and safety requirements specific to techniques to be executed

The following information will be generally provided in the Contract Documentation:

- Definition of objectives and control criteria
- Investigation data including subsurface geological information, hydrological data and geotechnical parameters
- Test data, borehole logs and recovered core samples
- Limitations including information on subsurface services
The following aspects, where applicable shall also be addressed:

Finishing off of treatment areas to specified lines and levels, whether materials are to be removed, removed and replaced by other materials,
processing of materials and all other measures to be carried out in meeting requirements as specified in Contract Documentation.
The Contractor shall provide a quality management plan indicating his proposed quality assurance testing program which shall allow, if necessary,
testing at each treatment position as required. Testing methods to be employed shall be as specified in the Contract Documentation.

The Contractor, where so specified, shall prepare a detailed construction proposal/design detailing all plant, equipment and materials to be
employed in meeting the sheet piling objectives and performance requirements detailed in the Contract Documentation as well as address all the
aspects given in Clause A12.4.4.1.
The Contractor shall be responsible for the acquisition and conveyance to site of sheet piling materials of suitable quality with manufacturer
specifications, the latter presented for approval by the Engineer prior to delivery/purchase.
Before commencement of any piling works, the Contractor shall submit a method statement to the Engineer for approval which shall include the
following information:
- Programme of works detailing sequence and timing of individual portions of the works
- Maximum proposed lead at any stage of driving between a pile and its neighbour and the limitations of same if hard driving is encountered
- Height, spacing, stability and type of piling guidance system and the number of piles in each panel (if applicable)
- Full details of installation plant to be utilised including manufacturers information, proof of servicing/ recent upkeep and assessment of actual
input energy to the piles and a definition of driving refusal for each type of plant proposed
- Proposed phasing of any excavation/ filling operations such that design stresses in the piles and frames/ supports are not exceeded
- Contingency plan in the event of encountering obstructions or reaching driving refusal to minimise disruption/ delay especially when using
pitch and drive methods
- Predicted noise levels and confirmation these are within statutory requirements
- Confirmation that vibration levels are within requirements of Contract Documentation.
Sheet pile design shall be carried out by competent personnel following on from relevant approved/ specified design requirements.
Engineer approval of the Contractor’s method statement shall not be unduly withheld with acceptance lead time as per Table A12.4.3-1.

The Contractor, where so specified, shall prepare a detailed construction proposal/design detailing all plant, equipment and materials to be
employed in meeting diaphragm wall objectives and performance requirements detailed in the Contract Documentation as well as address all the
aspects given in Clause A12.4.4.1.
Before commencement of any work, the Contractor shall submit to the Engineer a Method Statement for approval which shall include the following
information:
- Program of works detailing sequence and timing of individual portions of the works
- Full details of installation plant to be utilised including manufacturers information; proof of servicing/ recent upkeep; and logistics of planned
plant rotation to fulfil construction requirements
- Correct layout of panels and means to achieve this on the ground. The layout plan must take into consideration factors such as grab size;
wall plan shape; dimension of steel reinforcement cages, and site logistics
- Proposed panel rotation for excavation; reinforcement installation, and concreting
- Dimensions; depth (minimum 1,2 m), and strength of the concrete guide walls
- Proposed mixing; batching and removal to storage of bentonite slurry and a back-up plan for sudden loss of suspension
- Proposed method of reinforcement cage construction; pitching and installation
- Stop end type, insertion and removal with confirmation of panel edge recessing
- Steel sleeve (block-out) location and method of prop or tie-back anchorage
- Contingency plan in the event of encountering obstructions
- Confirmation that all requirements of Contract Documentation are being achieved.
Planning and construction of diaphragm walls shall be carried out by competent and experience construction personnel following on from relevant
approved/ specified design requirements.
Engineer approval of the Contractor’s method statement shall not be unduly withheld with acceptance lead time as per Table A12.4.3-1.
The Contractor shall be responsible for the design of a suitable cementitious concrete mix and bentonite slurry for construction of the diaphragm
wall which shall be presented by for approval by the Engineer with due consideration of the following:
Availability of cementitious products in the quantities required for production
The achievement of the specified characteristic strength in the mix
Workability of the concrete during displacement of the bentonite slurry

- Obtaining samples of the mix constituents
- Carrying out the mix designs
- Production of trial mixes in the laboratory to allow for the sampling and testing of concrete
- Production of trial mixes by production plant to allow for the sampling and testing of concrete
- Carrying out adjustments to the mix designs as may be required and repeating laboratory and production plant trial mixes to allow for the
sampling and testing of concrete
- Obtaining Engineer’s approval of the mix.
Concrete mix design shall be carried out by competent personnel following the relevant approved/ specified mix design procedures and SANS
Methods for the sampling, curing and testing procedures. The relative density as well as the fluidity of the various mixes shall be determined to
provide a basis for ongoing quality assurance during diaphragm wall construction.
The Contractor shall submit his proposed mix design for the concrete accompanied by all relevant information to the Engineer for approval. A lead
time, as per Table A12.4.3-1, is required for this information. Construction shall only proceed once the Engineer is satisfied that the mix meets the
minimum performance criteria specified including the 28 day characteristic strength of the concrete as specified in the Contract Documentation.
Any changes to the mix after the Engineer’s approval has been obtained shall only be permitted if approved in writing by the Engineer.
A12.4.5 MATERIALS
Sheet pile sections are available in ordered lengths. Recommended maximum lengths, as dictated mainly by handling and driving requirements
are as follows:
Table A12.4.5-1: Recommended sheet pile lengths
Moment of Inertia of Section cm4 Maximum recommended Typical wall thickness Typical section half
per metre width length in metres (mm) depth (mm)
4110 6
13513 14
23885 18 10,0 150
39831 23 10,5 220
49262 24 13,0 220
92298 26 19,0 230
Sheet pile lengths may be successfully extended by specialist welding of sections or shortened by cutting. Length changes must ensure no
damage or distortion occurs to adjacent piles.
Steel sheet pile sections are manufactured from various grades of steel in accordance with EN10249-1-1995 as per Table A12.4.5-2 below for
cold-formed U and Z sections:
Table A12.4.5-2: Steel grades
Minimum yield strength Tensile strength Rm
Grade of steel Former UK reference
ReH (MPa) (MPa)
S 235 JRC 235 340 – 470 40B
S 275 JRC 275 410 – 560 43B
S 355 JRC 355 490 – 630 50C
In hard driving conditions it may be necessary to increase the pile section size to achieve the required penetration and/ or adopt a higher grade
of steel. The Engineer’s approval shall be obtained before orders for any sheet pile sections are placed.
Piles shall be stacked on site in accordance with the manufacturer’s recommendations. The Contractor shall ensure that operations involving
loading, transporting, offloading, handling, stacking and pitching the piles, are carried out in a manner that shall prevent damage to them or their
coatings. The Engineer shall be immediately informed of any damage and the Contractor shall the submit proposals for remedial measures, the
cost of which shall be borne by the Contractor. Lifting holes shall not be burned or drilled through sheet pile without prior approval by the Engineer
and shall be made good after use. The same pile sections; lengths and steel grades shall be stored in different stacks clearly marked or colour-
coded to avoid placement errors.
Driving caps for diesel hammers shall be manufactured from cast steel and have an arrangement of guiding grooves for the different sheet pile
sections on its lower side. A wooden or plastic/composite dolly (cushion) shall be fitted into recesses on top of the driving cap.
Walers, tie-rods and ground anchors shall be as specified in the Contract Documentation.

A12.4.5.2 Diaphragm Wall
a) Bentonite slurry
Bentonite slurry is a viscous mixture of approximately 4 % - 6 % of bentonite powder by mass with water and be of such consistency that soil and
other heavy particles mixed with this bentonite slurry during excavation are held in suspension and do not settle to pile base.
Bentonite shall either be of sodium origin or calcium derivation and checked for required thixotropic properties, quality, moisture content, grading
and sand content.
b) Cement
Cement used in cementitious grout shall be CEMI or CEMII complying with SANS 50197 -1 or such other cements as specified in the Contract
Documentation. The Engineer may allow or specify the use of other cements and certain additives to improve workability of the tremied concrete
in order to optimise construction of the wall.
c) Water
Water used for batching of grout and bentonite slurry shall be potable, complying with SANS 51008.
d) Sand
Sand shall be clean, non-plastic, non-angular and well-graded particles sized from 0,06 – 2,0 mm.
e) Coarse aggregate
Coarse aggregate shall comprise of clean, durable, hard rock aggregate as per SANS 1083 or as specified in the Contract Documentation.
f) Steel
Steel for the reinforced cage shall be as indicated in the Contract Documentation and as per the requirements of this document.

a) Driving equipment
A wide variety of plant is available for sheet piling including small to large vibratory, drop, hydraulic, pneumatic, diesel hammers; employing various
techniques for insertion. Selection of plant shall be determined by its ability to install pile sections while considering economies of scale. Choice
of plant shall also be influenced by noise; vibration type and output for specific site locations. Equipment used shall be in good working order and
properly maintained.
b) Pile threader/ Guide frame
Pile threaders/ guide frames shall be used to interlock individual piles at ground level to eliminate manually guiding piles to interlock. Lifting
shackles are required to lift, and guide piles, into position in the threader.
c) Pile extractors
Sheet piles intended to serve only as temporary works shall be extracted for re-use by means of suitable pile extractors. Cranes used in extraction
shall have an appropriately sized jib to prevent damage when extraction forces are applied.
d) Ancillary equipment
All ancillary equipment (cranes; driving caps; generators, etc.) required to execute pile installation shall be fit-for-purpose.

a) Excavation equipment
Diaphragm wall panels shall be excavated using one or more of several types of equipment as may be appropriate to the project requirements
including:
- Hydraulic Cutters - These are capable of excavating even into rock but require large bentonite slurry plants and large cranes to hold cutters.
Steel mechanisms built into the grab body provide a high degree of verticality control.
- Hydraulic Grab - Hydraulic grabs have hydraulically operated closing jaws able to exert considerable closing force to excavate dense sand;
stiff clay, or soft/ very soft rock. They can include steering mechanisms.
- Cable Grab - Cable grabs use only pulley forces to close grab jaws and are more suited to soft ground
- Kelly Grab - Kelly grab types are rigidly suspended from a base machine opposed to rope-suspended grabs as detailed above. Kelly grabs
provide reasonable excavation force and verticality control but are slower than other methods.
Typical diaphragm wall widths are 0,6 to 1,5 m although other sizes may be constructed.
b) Bentonite slurry equipment
Bentonite slurry equipment shall comprise a storage facility for bulk or bagged material; colloidal mixer; hydration storage tank, and slurry pump.
Slurry mixing plants shall be equipped with high-speed/ high-shear colloidal mixers or high-velocity/high shear jet mixers used in conjunction with
a high-speed/high-shear centrifugal pump. Plant shall be equipped with a mechanically, or hydraulically, agitated sump and shall include pumps,
valves, hoses, supply lines, tools and other equipment and materials required to manufacture the slurry and deliver it in a continuous supply from
hydration ponds (or tanks) to diaphragm panels. Mixers shall be capable of achieving complete dispersion of bentonite and additives and shall be
capable of continual-mixing slurry to provide and maintain a uniform blend. Slurry pumps shall be of sufficient capacity to ensure adequate supply
of slurry during panel excavations and capable of pumping the concrete displaced slurry back to storage. Sufficient ponds or tanks for storage
shall be provided on site and fluid reserve capable of filling two panels shall be kept in stock in case of rapid loss of suspension. Slurry cleaning
equipment shall be available for cleaning of return slurry with equipment capable of reducing sand; sediment, or other solids as necessary. This
equipment may include but not be limited to vibratory shaker screens; centrifugal sand separators, and/or stilling ponds.

c) Concrete mixer
The concrete mixer used for manufacture of concrete and shall have sufficient capacity to ensure an adequate supply of concrete as required for
continuous production. This mixer shall be fitted with calibrated loadcells to enable the accurate weigh batching of cementitious materials.
d) Water supply
Water tank/s shall have sufficient capacity to ensure adequate supply during a working shift. Pumps used shall be of sufficient capacity to provide
the required flow and pressure.
e) Hoses

a) General
Works may only commence after the Engineers approval of the Contractors method statements as required by these and the Contract
Documentation.
The Contractor shall set out the works utilising appropriate and approved methods. The setting out shall be approved by the Engineer before piling
work commences.
b) Process
(i) Set-up
Sheet piles shall be lifted up one at a time and threaded one end into the other interlocking piles prior to driving. A crane shall be used
for this purpose and a pile threader/ guide frame/ or scaffold platform constructed to provide support for assembled sheets readied
for driving.
(ii) Driving
Sheet piles shall be installed by driving or vibrating into the ground. Driving can be achieved by the use of vibratory hammers; drop
hammers; or diesel, hydraulic or air hammers. Driving shall be by ‘Pitch and Pile’ where each pile or pile pair shall be driven to finished
level before repeating the operation – a method suited to relatively short piles in softer ground where obstructions are unlikely.
Alternatively, y ‘Panel Driving’, which is the more common method can be used. Once guide frames have been positioned for panel
driving the first pair of piles shall be carefully pitched, plumbed and partly driven to form a guide for adjacent piles. The remaining
panel of piles (usually 10 – 20 m run of wall panel) is then pitched and interlocked. The last pair of piles shall then be partially driven
followed by partial driving of the rest of the panel working back to the first pair in the panel. There shall be no departure from the
vertical. The top guide wailings can at this stage be removed and then all but the last pair of piles in the panel driven to level. The last
pair shall be left partially upstanding to form the guide pair for commencement of the next panel. It is essential, to ensure verticality,
and to make sure the pile driving hammer orientation is lined up with the pile axis.
Driving caps (also termed ‘helmets’) provide protection of the sheet pile head during driving. The cap shall be close fitting and rigid to
provide even energy distribution from a hammer blow. Buckling of steel sheet pile heads or damage to the heads of concrete piles
can otherwise occur in driving through very hard ground. In vibratory hammers a driving cap is unnecessary since the hammer clamps
the sheet pile hydraulically.
All changes to the initially approved method statements shall be approved in writing by the Engineer and all production work shall be
in strict accordance with the approved methodology and specifications.
(iii) Obstructions
When obstructions are encountered the remainder of the panel shall be completed so that the piles obstructed have support from
adjacent piles during attempts to drive through the obstruction. If unsuccessful, driving can continue whilst the obstruction is removed
thereby minimising construction delays. Sheet pile toes can be damaged when driving through cobble or boulder layers. Measures to
limit risk of damage include the use of sheet piles made from high tensile steel; reinforcement of the sheet pile toe by welding on
additional strengthening plates; and reducing hammer energy blow.
Pile toes shall, if necessary, be secured into underlying rock using steel pins. These may be required where it is not feasible to drive
piles to required penetration, or where there is concern piles may slide down a sloping rock surface. Pins shall be welded onto piles
before driving or installed via tubes attached to and driven with the piles. For the latter holes are drilled into rock and pins grouted into
position.
(iv) Ground pre-treatment
It may be cost effective to consider pre-treatment of ground to allow lighter section installation where piling is dominated by driving
rather than moment capacity. This could include:
Pre-auguring to weaken or replace hard ground
Driving a heavier section than required; extraction of the heavy unit followed by driving of working pile sheets in the same ground
Controlled blasting to reduce very dense soil or obstructions to granular material: without displacement.
(v) Water tightness
The only possibility of water infiltrating through a sheet pile is by flowing through the interlock. The interlock shape naturally provides
high resistance to seepage where sealing systems are unnecessary for applications such as temporary retaining walls where
moderate rates of seepage are acceptable. If medium to high seepage resistance is required double sheet piles or welding of joints
shall be required. Alternatively, elastic sealants such as silane modified polymers (MS-Polymers) shall be considered. Typically, the

sealant products manufactured with silyl modified polymers have good adhesion on a wide range of substrate materials, and have
good temperature and ultraviolet resistance.
For concrete sheet piles interlock shall be provided by tongue and groove methodology. One side of toe shall be chamfered to force
the concrete sheets to stay together during driving. A sealant grout sock shall provide water tightness.
Where seepage beneath installed sheet piles cannot be addressed by further driving of the piles it may be necessary to carry out
grouting to seal off the base to address water ingress. Provision is made for payment of such localised grouting. Where such grouting
is approved by the Engineer, it shall be carried out in accordance with the applicable specifications for the technique utilised.
(vi) Durability of steel sheet piles

Life of a sheet pile wall is very much dependant on corrosiveness of the surrounding environment, and the South African coastline in
particular is a highly corrosive making for poor permanent marine sheet pile applications. Corrosion is usually lowest in the buried
section of the wall; followed next by the zone permanently below water; with the zone above the minimum water level requiring
extensive corrosive protection coatings of the highest quality.
The service life of a sheet pile wall shall be extended by one or a combination, of the following as specified in the Contract
Documentation:
- Protection coating by first light shot blasting (sheet piles are received without any protective coating) followed by application of
Tar Vinyl (an aromatic pitch modified with suitable vinyl resins) in coat thickness up to 150 microns; or blasted clean followed by
application of High-Build Isocyanate cured, Epoxy Pitch (special coal tar pitch, modified with epoxy resins, cured with isocyanate
adducts) in coat thickness up to 400 microns; or painting via a wide range of epoxy primers (seawater immersion & chemical
resistance), polyurethanes (for colour and gloss retention) up to 480 microns
- Use of stronger section or higher steel grade to create a ‘statical reserve’
- Use of Marine Grade Steel (ASTM A690) in the splash zone
- Avoiding significant bending moments in high corrosion zones
- Extension of the concrete capping beams to below the low-water level
- Cathodic protection by impressed sacrificial anodes which constantly protect surfaces in contact with water
- Special corrosion resistant steel in the permanent and low water zone where maximum bending moments and consequent
highest steel stresses derive. Tests indicate loss of steel thickness can be reduced by a factor of 3 in the permanent immersion
zone and 5 in the low water zone when compared to standard structural steel
c) Anchors
Where ground anchors are required they shall conform to specification of Section A12.2: Ground Anchors. Tie-rods shall be suitably sized,
corrosion-protected steel bars, tied between pile walls and anchorages.
Anchored raked piles shall also be considered as anchorage.
The Contractor shall, on a continuous basis and at an agreed frequency, monitor ground or movements of structures with sufficient accuracy to
ensure that any displacements are within specified allowable tolerances. The proposed method of monitoring shall be approved by the Engineer
before any works are commenced.
Daily records shall be kept of all works, materials utilised and quality control activities carried out in accordance with Contract Documentation and
the approved method statements. These records shall be submitted to the Engineer before noon on the following working day and shall include:
- Daily records of all sheet piling positions, driving depths, lateral extents, start and stop times, piling equipment, anchorage installed, details of
all stoppages, breakdowns and m2 of sheet pile installation completed at each position
- Daily records of sheet piles used, driving type and effort, and other details that may be required for measurement purposes
- Results of routine consistency tests in terms of sheet pile verticality and horizontal alignment;
- Results of pull-out tests on anchors
- Details of daily excavation and support measures (type, number, location)
- Any change in subsurface conditions which have, or may affect, changes in methodology or progress.

a) General
Prior to commencing with production, the Contractor shall provide the Engineer with a plan showing the proposed rotation sequence of panel
construction for approval. Operational matters such as waste disposal shall also be addressed.
b) Trials
The Contractor shall be required to construct a trial panel as specified in the Contract Documentation and shall allow for the Engineer’s assessment
of this panel. This will require partial exposure of the completed panel to ascertain whether it meets specified requirements in terms of verticality;
dimensions, and uniformity, and to allow execution of tests and measurements for quality assessment purposes. Trial panels shall be placed to
eventually become part of the completed diaphragm wall. Trial panels shall have assigned test parameters agreed with the Engineer and shall be
exposed by excavation to the depths indicated in Contract Documentation to allow visual appraisal, dimensional and geometric measurements
and integrity testing. Successfully installed trial panels meeting the specified requirements shall be measured for payment. Defective panels shall
be assessed by the Engineer as per Clause A12.4.8. All excavations shall be backfilled in 150 mm thick layers using the excavated or other
approved materials to the specified density. Construction of the test panels shall be witnessed by the Engineer.

c) Construction
(i) Guidewall
A shallow guide wall shall first be constructed on the alignment of the proposed wall. The guide wall serves to locate the excavation
equipment within acceptable tolerances before the diaphragm wall construction commences. It shall be constructed from reinforced
concrete typically 1,0 to 1,5 m deep. Walls shall be constructed to tight verticality tolerance.
(ii) Excavation
Excavation for diaphragm walls shall be carried out in panel widths. A typical panel is excavated in three bites; a left bite, a right bite
and lastly removal of a middle dumpling. Bite widths depend on the grab type used but 2,0 to 2,8 m wide, and 0,3 to 1,5 m wide, is
typical, with panels 3,0 to 6,0 m wide requiring rotated bites. Simultaneously with soil removal, bentonite slurry shall be pumped into
the excavation to support the surrounding soil preventing collapse into the excavated trench. Excavation shall continue until all bites
reach design depth.
(iii) Bentonite slurry
Bentonite slurry shall be batched in on-site plant; allowed to hydrate to gain full gelling properties, before being used for temporary
excavation support. Bentonite powder in bulk, or bagged form, shall be added to water and rapidly mixed in a colloidal mixer to
produce desired concentrations of bentonite slurry. Slurry shall be pumped to a storage tank for hydration for approximately 12 hours.
Bentonite particles swell and absorb water before use to support excavations and shall be fully hydrated to design requirements before
use. Hydrated slurry, or recycled slurry/ mud, or a mixture of the two shall be pumped into the excavation trench to replace excavated
soil, maintaining a constant head of slurry above prevailing in situ groundwater levels. Quality of the slurry is paramount in obviating
problems of slurry trappings on steel reinforcing elements. Excavation of the panels continues under slurry until both left; right and
centre bites are excavated down to the required panel toe level. Slurry shall maintain a minimum1,5 m positive head above the water
table in order to create a 2,0 to 3,0 mm impermeable bentonite cake on the excavation sidewalls.
(iv) Concrete
Concrete shall have high workability, utilising using well-rounded aggregate and high slump so that it behaves in placement as a
heavy viscous fluid. Vibration shall not be used as it promotes segregation with compaction achieved by gravity deemed adequate.
Distance of lateral flow required to fill a panel or panel section from any single tremie position shall be limited to 2,5 – 3,0 m.
(v) Stop-ends
Steel or precast concrete stop-ends shall be inserted at the edges of excavated panels. These stop-ends may contain a rubber water
bar that is later embedded into the concrete panel. Water bars minimise water ingress between panel joints once earth is excavated
inside diaphragm wall. The stop-end is removed from the cast panel during excavation of the following panel.
(vi) Steel reinforcement cage
The prefabricated steel reinforcement cage shall be carefully lowered into the excavation between stop ends. Block-outs for floor slab
connections; ground anchors or other penetrations shall be included within the reinforcement cage. The cage shall be secured in
position by approved means to ensure the specified inclination and cover is maintained.
(vii) Concreting
Concrete shall be placed using a tremie. Concrete shall have a slump of 150 – 200 mm and poured using a hopper and steel tremie
tube extending to the base of the excavation.
Typically, two hoppers are used for a 6,0 m wide panel. Hoppers and tubes shall be charged with concrete before lifting off the
excavation base allowing concrete to flow and displace overlying bentonite upwards. Bentonite shall be pumped back to the recycling
plant as it is displaced. Tremie pipe lengths shall be shortened as concrete level rises in panels to ensure fresh concrete is present
at the bentonite/ concrete interfaces. The discharge end of the tremie shall be at least 500 mm below the surface of the concrete.
Tremie pipes shall be removed when concrete rises to required levels. Concrete shall be cast to a minimum of 750 mm above the
required cut-off level and finished according to the Contract Documentation.
(viii) Panel rotation
The first panel constructed in a run of wall is termed a primary panel. During concreting excavation grab and base crane shall be
moved to a second location away from concreted panel to a position as designed by the Contractor to achieve his planned panel
construction rotation. There excavation shall be commenced on a second primary panel. The newly excavated panel shall then be
completed and concreted in the same manner as previously described. Subsequent panels completed adjacent to completed panels
are termed secondary or running panels. The final panel completed in a run of wall is termed the closing panel since it closes out the
length of wall.
(ix) Spoil
The Contractor shall, at his own cost, remove all spoil from the site and at all times ensure a clean and orderly workspace.
d) Water tightness
Water tightness shall be ensured through care in ensuring formation of the required recess through stop-end retrieval. A water stop shall be
considered when an impermeable condition is sought.
e) Anchors
Where ground anchors are required these shall be specified in the Contract Documentation and the requirements given in Section A12.2: Ground
Anchors and shall be installed at the specified locations .
f) Obstructions
Obstructions encountered during construction shall be dealt with as per the Contractor’s plan methodology presented and agreed as in Clause
A12.4.4.3.

g) Monitoring and records
Monitoring and logging of all diaphragm wall construction operations shall be undertaken by Contractor and records shall be submitted to Engineer
before noon the following working day.
The records shall include:
- Daily records of all panel positions; depths of excavation, start and stop times, all construction parameters used, details of all stoppages,
breakdowns, slurry and concrete pumped at each position.
- Daily records of excavation quantities; bentonite usage, cement usage; steel installed; and any other details that may be required for
measurement purposes.
- Results of routine consistency tests (flow cone, density tests as specified) carried out on all batches of bentonite/ concrete mixed and
utilised,
- Any change in subsurface conditions which have or may affect changes in methodology or progress.
- Spoil volumes
- Details of anchors placed
Records shall be in a format agreed with the Engineer.
A12.4.8 WORKMANSHIP
A12.4.8.1 General
The Engineer shall undertake routine inspections and conduct routine tests to determine whether the quality of materials and workmanship
provided comply with the requirements of this section. Test results and measurements will be assessed by the Engineer for compliance with the
requirements specified in the Contract Documentation. The Contractor shall carry out the necessary process control measures required in terms
of Clause A1.2.8.1 of Chapter 1, as indicated in the approved Quality Assurance Plan and as may be specified in the Contract Documentation.

The following approved quality control measures shall be carried out as may be applicable and as may be specified in the Contract Documentation
a) Evaluation of exposed sheet pile walls
The Engineer shall inspect the exposed sheet pile sections for final workmanship; finishing off; horizontal and vertical alignment; and anchor
installations. Where walls are required for water control purposes borehole permeability tests may be specified in the Contract Documentation.
b) Pull-out tests
Pull-out tests on anchors shall be performed according to Section A12.2: Ground Anchors and any other tests as may be prescribed in the Contract
Documentation.

The following approved quality control measures shall be carried out as may be applicable and as may be specified in the Contract Documentation.
a) Evaluation of exposed diaphragm panel tops
The Engineer will direct which upper portions of which panels are to be exposed for uniformity, verticality and width measurements and for further
testing. Such testing may comprise coring 100 mm diameter cores from top or from the exposed sides of exposed panels. Where specified, full
length coring of the completed panels shall be carried out utilising appropriate, approved equipment, bits and core barrels in the size indicated.
Testing of selected core lengths may be instructed to prove the strength of the constructed panels. Where diaphragm walls are required for water
control purposes borehole permeability tests may be specified in the Contract Documentation. All core holes shall be reinstated with a suitable
non shrink grout as approved by the Engineer. Backfilling of any excavations shall be done in 150 mm thick layers using the excavated or other
approved materials to the specified density.
b) Acceptance criteria
The characteristic strength of concrete shall be as specified in the Contract Documentation. Results of strength tests on the concrete shall be
assessed according to Clause 20.1.7.5d) (Judgement Plan B) of Chapter 20.
(i) Concrete panels:
Testing on completed / cast concrete panels shall be carried out as follows;
- UCS Testing of 100 mm diameter, 200-250 mm long drilled cores from constructed panels
- Coring the centre of constructed panels and UCS testing of selected cores
- Indicative compressive strength tests on 100 mm cubes made from concrete mix
- Any other tests as may be prescribed in the Contract Documentation
(ii) Concrete
- Consistency - The consistency and workability of each batch of concrete shall be tested for consistency with the Slump Cone.
The slump shall be more than 150 mm and less than 200 mm. Ranges in values shall be determined as works proceed and any
significant variation from running average shall be immediately investigated and brought to the attention of the Engineer.
- Concrete Cube Strength Testing - 150 mm cubes shall be made, cured and tested in accordance with SANS 3001-CO11 at
frequencies specified in the Contract Documentation. Three cubes per test shall be required. The results of strength tests on the
concrete shall be assessed according to Clause A20.1.7.5d) (Judgement Plan B) of Chapter 20.
c) Bentonite slurry
A minimum of 2 samples of bentonite slurry shall be sampled daily. One 0,3 m below the panel surface and a second one at panel mid-depth for
process control testing by the Contractor. Important parameters for testing are:
- Measure of rheology to ensure slurry is appropriately fluid
- Slurry density prior to concreting to ensure satisfactory displacement
- Sand content to determine re-use

- pH of fresh bentonite
- pH of slurry as check for cement or other contamination
- Filtrate loss to check ability to form a seal (surface filtration via ‘filter cake’ formation) or geared toward deep filtration (percolating through
the filter cake) or rheological blocking (flow until restrained by shear strength)
The Engineer shall generally request testing to determine the density; viscosity (Marsh Cone); Fluid loss; pH, and sand content to verify uniformity
and compliance with the parameters established in the mix design and that listed in Table A12.4.8-1: Acceptance criteria below.
d) Acceptance criteria
Acceptance or rejection shall be based on the Contractor’s ability to achieve the specified criteria which may include:
(i) For concrete
- Required consistency and workability
- Attainment of 28 day specified characteristic strength of concrete cubes,
- Attainment of specified UCS results on cores,
(ii) For bentonite powder**:
- Yield Point/ Plastic Viscosity Ratio of maximum 6
- Plastic viscosity greater than 10
- Moisture contentless than 15 %
- Less than 2,5 % remaining on a 75 micron sieve
- A 6,4 % suspension of bentonite in distilled water, aged for 24 hours, should have a minimum viscometer dial reading of 30 at 600
rpm (American Petroleum Institute (API)RP13B).
**FEDERATION OF PILING SPECIALISTS BENTONITE SUPPORT FLUIDS IN CIVIL ENGINEERING January 2006
(iii) For bentonite slurry:
The following table (API) provides acceptance criteria:
Table A12.4.8-1: Acceptance criteria
Stages
Property Units Fresh Ready for re-use Before Test equipment
concreting
Density g/ml <1,10 <1,25 <1,15 Mud balance

Marsh viscosity
sec 32 - 50 32 - 60 32 - 50 Marsh funnel
(946ml)
Fluid loss (30 min) ml <30 <50 n/a Filter press
pH 7 - 11 7 - 12 n/a pH meter
Sand content % n/a n/a <4 Sand content set
A12.4.8.4 Performance monitoring

Where so specified in the Contract Documentation wall movements shall be monitored by survey of other approved methods to ensure the
safety of any excavations and/or the efficacy of the support installed.

B12.4 LATERAL SUPPORT
CONTENTS
B12.4.1 SCOPE
B12.4.2 DEFINITIONS
B12.4.3 GENERAL
B12.4.5 MATERIALS
B12.4.8 WORKMANSHIP
B12.4.1 SCOPE
B12.4.2 DEFINITIONS
B12.4.3 GENERAL

B12.4.5 MATERIALS


B12.4.8 WORKMANSHIP

C12.4 LATERAL SUPPORT
(i) Preamble
pay items.
C12.4.1 Site Establishment
C12.4.1.1 Sheet Piling lump sum
C12.4.1.2 Diaphragm Walls lump sum
The unit of measurement shall be the lump sum.

The tendered lump sum for site establishment shall include full compensation for establishing all necessary plant, equipment and services on
site to carry out the works as specified including all work in preparing the works area for construction activities and subsequent removal from
site of all such plant and equipment including all temporary works such as access roads, staging, platforms, coffer dams and such like.
The work will be paid for by way of a lump sum, 50 % of which shall be payable when all major necessary equipment is on site, trials (if any) are
completed and the first production work started. The second instalment of 25 % is payable after half the specified work is complete. The final
instalment shall be payable after all work is complete, all equipment removed and the site restored as specified in the Contract Documentation.

C12.4.2 Moving to and setting up equipment at sections or sites to be defined
C12.4.2.1 Sheet Piling number (No)
C12.4.2.2 Diaphragm Walls number (No)
The unit of measurement shall be the number of positions to which equipment is moved and set up in position to execute the works as described in
the Contract Documentation. The quantity measured shall be the number of set ups at designated works positions (individual pile position, or panel
section of steel sheet piles, or diaphragm panel, as specified) inclusive of approved trial works positions as well as any additional positions as may be
The tendered rates shall include full compensation for all costs involved in moving to and setting up required equipment at each works position.
Tendered rates shall include all costs in setting-up equipment and subsequent decommissioning.
C12.4.3 Setting out of works at sheet piling or diaphragm panel positions metre (m)
The unit of measurement shall be metres in length set out by a registered surveyor as per the Contract Documentation or as instructed by the Engineer.
The tendered rate shall include for all costs incurred in setting out the works inclusive of transport, labour and all incidentals required to carry out the
work as specified. Payment will not be made for the re-setting out of positions lost for whatever reason.
C12.4.4 Sheet pile driving (individual sheet pile type or sheet panel extent specified) square metre (m2)
The unit of measurement shall be the net square metre of sheet piles installed.
The tendered rate shall include full compensation for supply of sheet piles to site; correct handling and storage of sheet pile elements, driven
installation and for all labour, plant and equipment required for installation to depths as required by the Contract Documentation, or as instructed
by the Engineer.
C12.4.5 Sheet pile extraction square metre (m2)
The unit of measurement shall be the area of pile sheet extracted.

The tendered rate shall include full compensation for sheet piles extracted, handling and storage; and ultimate removal from site inclusive of all
labour, plant and equipment required for these works as required by the Contract Documentation, or as instructed by the Engineer.
C12.4.6 Sheet pile and diaphragm wall supports (as specified)
C12.4.6.1 Props number (No)
C12.4.6.2 Anchors number (No)
C12.4.6.3 Tie-bars number (No)
The unit of measurement shall be the number of props or anchors or tie-bars (including designed deadman anchorages).
The tendered rate shall include full compensation for installation to Contract Documentation detail, including all labour, plant, materials and
equipment required.
C12.4.7 Sheet pile grouting
C12.4.7.1 Chemical grouting kilogram (kg)
C12.4.7.2 Jet grouting kilogram (kg)
C12.4.7.3 Compaction grouting kilogram (kg)
The unit of measurement shall be the kilograms (kg) of chemical or cement actually utilised for grouting as specified and approved by the Engineer.
The tendered rates shall include for all labour, plant, equipment, materials, delivery, storing, mixing, pumping, drilling, injection and all incidentals
required. No payment will be made for any wastage or for rejected batches. Only verified quantities will be accepted for measurement and payment.
The rates shall include quality control measures, testing of materials, monitoring and supervision of the works and the provision of daily records for all
items specified in the Contract Documentation.

C12.4.8 Concrete placed by tremie under slurry in diaphragm walls (class of concrete indicated) cubic metre (m3)
The unit of measurement shall be the cubic metre (m3) of concrete placed by tremie under bentonite slurry for the construction of diaphragm walls.
The tendered rate shall include full compensation for supplying and storing all material, providing all plant, mixing, transporting and placing the concrete
by tremie methods
C12.4.9 Partial Excavation of Panels cubic metre (m3)
The unit of measurement shall be the cubic metre (m3) of material excavated for inspections and testing adjacent to panels and removed to stockpile
for backfilling operations or to spoil.
The tendered rate shall include full compensation for the excavation to expose the panels and shall include for the backfilling thereof as specified.
The rate shall include for all labour, plant and equipment required for such removal and backfilling as required by the Contract Documentation, or
as instructed by the Engineer. No overbreak shall be paid for excavation beyond the theoretical excavation boundaries.
C12.4.10 Cement, additives, bentonite, aggregate and fillers )
C12.4.10.1 Cement kilogram (kg)
C12.4.10.2 Bentonite kilogram (kg)
C12.4.10.3 Fine/ coarse aggregate (specify) kilogram (kg)
C12.4.10.4 Other fillers (specify) kilogram (kg)
The unit of measurement shall be the kilogram of materials actually utilised for diaphragm wall construction as specified and approved by the Engineer.
The tendered rates shall include for all labour, plant, equipment, materials, delivery, storing, mixing, pumping, placement and all incidentals required.
No payment will be made for wastage or rejected batches. Only verified quantities will be accepted for measurement and payment.
The rates shall include quality control measures, testing of materials, monitoring and supervision of the works, daily records of all items specified in
C12.4.11 Bentonite slurry re-use cubic metre (m3)
The unit of measurement shall be the volume of bentonite slurry pumped for re-use.
The tendered rate for re-used bentonite slurry shall be for full compensation of pumping from completed panels to storage; cleaning and removal
of sand from used slurry to design standards; storage and pumping to new panel positions. Rates shall include for all plant; labour and equipment
necessary for this process. All activities associated with bentonite slurry re-use shall be to the requirements of the Contract Documentation, or as
C12.4.12 Steel reinforcement ton (t)
The unit of measure for steel bars shall be the ton of reinforcing steel in place in accordance with the drawings or as authorised.
The tendered rate shall be for full compensation in procuring the steel, bending, cage reinforcement construction, pitching and installation and
shall include for all plant required for reinforcement cage installation; labour and equipment necessary
C12.4.13 Exposing tops of selected concrete panels number (No)
The unit of measurement shall be the number of concrete panel tops exposed for inspection, measurement and testing.
The tendered rate shall include for all plant, excavating the material around selected panels as well as backfilling of excavations with suitable approved
material in 150mm layers compacted to the required density.
C12.4.14 Coring of concrete panels
C12.4.14.1 Setting up at completed panels number (No)
C12.4.14.2 Drilling and core recovery (size indicated) metre (m)
C12.4.14.3 Provision of core boxes number (No)
C12.4.14.4 Extra-over for inclined drilling metre (m)

The unit of measurement shall be per set-up at coring positions selected and pointed out by the Engineer; length of core actually recovered; the
provision of core boxes capable of accommodating a minimum 7,5 m of core, and for inclined drilling into panel sides.
The tendered rate shall include for establishment; labour, plant, delivery, core storage, monitoring, drilling supervision, core logging, removal of
samples for laboratory testing, and demobilisation shall be included in the above rates tendered.

D12.4 LATERAL SUPPORT
CONTENTS
D12.4.1 SCOPE
D12.4.2 GENERAL

12.5 SHOTCRETE
CONTENTS
A12.5.1 SCOPE
A12.5.2 DEFINITIONS
A12.5.3 GENERAL
A12.5.5 MATERIALS
A12.5.8 WORKMANSHIP

A12.5 SHOTCRETE
A12.5.1 SCOPE
This Section covers supply and application of shotcrete to rock and soil cut faces, soil nail faces, slope stabilisation and slope remediation, and
other areas as directed by the Engineer. It includes supply and application of shotcrete by either dry or wet-mix methods and for reinforcement
included in shotcrete layers. Sprayed concrete applied onto concrete faces is covered in Section A14.6 of Chapter 14: Rehabilitation of Structures.
A12.5.2 DEFINITIONS
Dry-mix shotcrete - constituent materials, comprising of a mixture of cementitious binder and aggregates, are mixed and delivered to the application
nozzle in dry form. Water and admixtures are added at the application nozzle under high pressure while being sprayed onto the receiving surface.
Shotcrete - means mortar or concrete which can be pneumatically projected at high velocity onto a surface.
Dental Shotcrete - is shotcrete applied to fill/cover or repair of a specific area/feature.
Shotcreting - is the process whereby mortar or concrete is pneumatically projected at high velocity onto a surface. It can comprise of dry-mix or wet-
mix shotcreting.
Wet-mix shotcrete - constituent materials, comprising of a mixture of cementitious binder, aggregates, water and admixtures, are premixed and
delivered to the application nozzle as a wet-mix before being sprayed onto the receiving surface.
A12.5.3 GENERAL


All materials used in the works described hereunder shall meet the appropriate standards given below and/or specified in the Contract Documentation
and shall be subject to the approval of the Engineer. The Contractor shall submit product certificates, conformance documentation (as per Part D)
of the works:
Table A12.5.3-1: Approvals required
A12.5.4.2 Shotcrete mix design 6 weeks before
construction
Materials Approvals
A12.5.5.4 Admixtures 1 week prior to use
A12.5.5.11 Curing compounds 1 week prior to use
A12.5.5.4 Test panels 6 weeks before
construction
Construction Method Statements*

A12.5.7 Method statements 6 weeks before
construction
A12.5.7.6 Fixing systems for reinforcement 1 week prior to use
* Including all relevant information

A12.5.4.1 General
The Contractor shall design the shotcrete mix used in carrying out the works as specified. Mix designs shall be complete, be presented on the
required forms and shall be presented to the Engineer with samples of all the constituents as required at least 6 weeks prior to placement
Where design by the Contractor for any technique to be carried out, is, in terms of the Contract Documentation, the responsibility of the Contractor,
all aspects given below shall be taken into consideration in carrying out these obligations.
The following shall be specified (where applicable) by the Engineer and reflected in the Contract Documentation:
- Limits of the area and thickness/ cover
- Shotcrete mix composition
- Shotcrete pigmentation
- Shotcrete strengths, post treatment properties, durability and any other deliverables as may be appropriate
- Layout of treatment positions
- Sequence of shotcrete applications
- Ancillary items such as reinforcing and drainage
- Quantities of shotcrete to be used
- Monitoring of works
- Measureable properties to be achieved over the life span of the project
- Environmental and safety requirements specific to the techniques to be executed

- A definition of the objectives and the control criteria
The following additional aspects, shall also be addressed where applicable:

- Finishing off of treatment area to specified lines and levels, whether materials are to be removed, removed and replaced by other materials,
processing of materials and all other measure to be carried out in meeting requirements as specified in the Contract Documentation.
- The Contractor shall provide a quality management plan indicating his proposed quality assurance testing program which shall allow for
testing at each treatment position. Testing methods to be employed shall be as specified in the Contract Documentation.

A12.5.4.2 Shotcreting
Where so specified the Contractor shall prepare a detailed construction proposal detailing all plant, equipment and materials to be employed in
meeting the geotechnical shotcreting objectives and performance requirements detailed in the Contract Documentation. In compliance herewith
the Contractor shall address all the aspects given in Clause A12.5.4.1.
The Contractor shall be responsible for the design of a suitable cementitious mix for shotcreting which shall be presented for approval by the
Engineer with due consideration of the following:
- Availability of cementitious products in the quantities required for production
- Achievement of specified characteristic strength in the mix
- Consistency and pump-ability of the shotcrete

- Obtaining samples of mix constituents with verification of required properties through laboratory testing
- Carrying out mix designs
- Production of trial mixes in the laboratory to allow for sampling and testing of shotcrete
- Production of trial mixes by production plant to allow for the sampling and testing of the shotcrete test panels
- Carrying out adjustments to mix designs as may be required and repeating laboratory and production plant trial mixes to allow for
sampling and testing of shotcrete
- Obtaining the Engineer’s approval of the mix.
Note that the above design shall be carried out by competent personnel following the relevant approved/ specified mix design procedures. Slump
of various mixes shall be determined to provide a basis for ongoing quality assurance during production shotcreting.
The Contractor shall submit his proposed cementitious shotcrete mix design for shotcreting accompanied by all relevant information for approval
by the Engineer. Lead time as per Table A12.5.3-1 is required for this information. It should be noted that shotcreting will only permitted to proceed
if the Engineer is satisfied that the mix meets the minimum performance criteria specified including 28 day characteristic strength of the shotcrete
as specified in the Contract Documentation.
Any changes to the mix after the Engineer’s approval shall only be permitted if approved in writing by the Engineer.
A12.5.5 MATERIALS
Refer to Clause A14.4.5.2a) of Chapter 14.
a) Cement
Cement shall be CEM I or CEM II with a strength class of 42,5 or greater. Where site blends are proposed, they shall conform to the particular
requirements of SANS 50197 - 1. (As per Clause A14.4.5.2a) of Chapter 14).
b) Supplementary cementitious materials
Refer to Clause A13.4.5.1b) of Chapter 13.
A12.5.5.2 Aggregates
Aggregate shall conform to the requirements of Clause A13.4.5.7 of Chapter 13 and SANS 1083.
A12.5.5.3 Water
Water used for batching of shotcrete hall be potable, complying with SANS 51008.
The supply of water to the mixing nozzle shall be such that a pressure of at least 400 kPa can be maintained.
A12.5.5.4 Admixtures
Shotcrete admixtures shall comply with SANS 50934 and shall be submitted to the Engineer together with the proposed mix design for approval
prior to commencement of work. Admixtures shall have no deleterious effects on reinforcement or shotcrete, and shall not contain any chlorides,
nitrates, sulphides or sulphites. Where more than one admixture is included in the shotcrete mixture, they shall be chemically compatible. Approval
of the shotcrete admixture shall be subject to satisfactory demonstration of suitability of the proposed shotcrete mixture through the construction
of trial panels and acceptable quality assessments conducted on a minimum of three test panels representing three independently batched
shotcrete mixes.
A12.5.5.5 Integral permeability reducing technology

Refer to Clause A13.4.5.5 of Chapter 13.
A12.5.5.6 Pigments and colouring agents

Pigments and colouring agents shall comply with the requirements of Clause A14.6.5.6 of Chapter 14.
A12.5.5.7 Fibres
Fibres shall conform to the requirements of Clause A14.6.5.7 of Chapter 14.
A12.5.5.8 Reinforcement
All reinforcement shall comply with Section A13.3 of Chapter 13. Reinforcement type and description shall be welded steel fabric mesh reference
number 395 (SANS 1024) unless otherwise specified in the drawings or Contract Documentation.

A12.5.5.9 Compressive strength, ultimate flexural strength and energy absorption capacity
The Contractor shall be responsible for design of the shotcrete mix in order to produce shotcrete that complies with the requirements for each
class of shotcrete.
Class of shotcrete is indicated by the designated code SP, the characteristic cylinder compressive strength in MPa at 28 days. For example, SP25
means shotcrete with a characteristic cylinder strength of 25 MPa after 28 days.
Minimum ultimate flexural strength requirements shall be as shown in drawings or as specified in the Contract Documentation.
In special applications, reinforcement in the form of flexible high tensile wire mesh, double twist mesh and chain link-type systems shall be
specified in the Contract Documentation or shown on drawings as encapsulated in shotcrete. Particular details of the earth spikes, soil nails,
rockbolts and other reinforcement fastening system shall be shown on the drawings or specified in the Contract Documentation.
Where required, the minimum energy absorption capacity of fibre reinforced shotcrete shall be specified in the Contract Documentation or indicated
on the drawings. Energy absorption capacity shall be determined from a slab specimen, tested at 28 days in accordance with EN 14488-5.
A12.5.5.10 Drainage systems, geopipe collectors and weepholes

Weephole material shall be U-PVC pipes and shall comply with SANS 966-1.
Water collection geopipes shall be perforated or slotted U-PVC pipes that comply with SANS 791.The size of perforations in perforated pipes shall
in all cases be 8,0 mm in diameter plus or minus 1,5 mm, and the number of perforations per metre shall not be fewer than twenty-six for 100 mm
pipes and fifty-two for 150 mm pipes. Perforations shall be spaced in two rows for 100 mm pipes and in four rows for 150 mm pipes. Slotted pipes
shall have a slot width of 8,0 mm with a tolerance of 1,5 mm. Arrangement of slots shall be subject to approval by the Engineer, but the total slot
area shall not be less than that specified for perforations. Installed pipes shall protrude 20 mm beyond the surface of final shotcrete layer and
have their inner slotted section end wrapped with a single layer of approved geosynthetic.
Pipes without slots or perforations required for transporting water from the drainage system to point of discharge shall be U-PVC.
Geocomposite/geosynthetic drains shall be of type specified in the Contract Documentation and shown on the drawings. Strip or band drains
generally 150mm wide geosynthetic which discharge into weepholes installed through shotcrete lining are commonly specified. Such shall be
detailed on the drawings where these drain types are specified.
These materials shall be protected against sunlight and mechanical damage during storage and installation. Geosynthetics shall be non-woven,
spun or thermic-bonded filament consisting of more than 85 % by mass of polypropylene, polyester or other approved material and manufactured
for civil-Engineering applications by a recognised manufacturer.
In special applications requiring particular drainage measures, shotcrete may require application over vegetation, matting or other bonded open-
structured geosynthetic. Geosynthetic requirements shall be specified in the Contract Documentation and shown on drawings.
A12.5.5.11 Curing compound

a) General
Refer to Clause A13.4.5.8 of Chapter 13.
b) Storing materials
Constituent materials shall be stored and handled so that quality is not impaired, for example by action of climates, intermingling or contamination,
and that their conformity with the respective standard is maintained.
c) Cement
Cement stored on the site shall be kept under cover which provides adequate protection against moisture and other factors which may promote
deterioration.
Cement supplied in bags shall be closely and neatly stacked to a height less than twelve bags and arranged so that they will not be in contact with
ground, floors or walls, and can be used in the order in which they were delivered to site.
Cement supplied in bulk shall be stored in waterproof containers designed to prevent any dead spots from forming.
Cement drawn for use shall be measured by mass.
Cement shall not be kept in storage for more than 8 weeks without the Engineer’s approval and different brands or types of cement shall be stored
separately as determined by the manufacturer’s requirements.
d) Pre-bagged shotcrete mixture
Dry pre-bagged shotcrete mixtures shall comply with EN1504-3 and shall be stored on site according to the requirements for storing
cement. Pre-bagged shotcrete mixtures shall not exceed shelf life determined by manufacturer and shall not be kept in storage for
longer than eight weeks without the Engineer’s permission.
e) Aggregates
Aggregates stockpiled on site shall not be contaminated.
Aggregates of different nominal sizes shall be stored separately and in such a manner to avoid segregation from occurring. Intermixing of different
materials and contamination by foreign matter shall be avoided. Aggregates exposed to a marine environment shall be covered to protect them
from salt contamination.
Fine aggregate shall be stored in such a manner that moisture content is kept constant at all times. The moisture content of fine aggregate
stockpiles shall be less than 8 % by mass when a dry mix shotcrete is used.
Where shotcrete is batched on site, aggregates shall be stored in covered heaps placed on a suitable impermeable floor lining to prevent
contamination during storing and handling aggregate. This lining shall be sloped to facilitate drainage.

f) Storage capacity
Storage capacity provided and quantity of material stored, whether cement, aggregates, admixtures or water, shall be sufficient to ensure that no
interruptions to work-progress of the project is occasioned by any lack of materials.
g) Deteriorated material
Deteriorated, contaminated or otherwise damaged material shall not be used in shotcrete. Rebound material shall be deemed to be contaminated
material. Such material shall be removed from site and spoiled without delay.

A12.5.6.1 General
Plant used for shotcreting shall be based on proven technology within the industry and shall be in good working order. Plant shall be inspected,
serviced and calibrated at regular intervals and tested to ensure system functionality, efficiency and accuracy; all to Engineer-satisfaction.
A12.5.6.2 Spraying equipment

Type and capacity of delivery hoses and nozzles shall be such as to ensure a uniform mix and supply of mix ingredients to mixing nozzle, thereby
obtaining correct consistency and a uniform discharge rate from nozzle.
The Contractor shall provide on-site a standby hose of capacity similar to the one in use to maintain continuity of work in case of a hose blockage.
Hoses shall be blown clean before any work is stopped.
a) Dry-mix process
Air operating pressure supply at the gun outlet shall be greater than 240 kPa, and shall, as a minimum, be capable at all times of maintaining a
discharge nozzle velocity of 90 to 120 m/sec. Water added at nozzle shall be supplied at a uniform pressure of 100kPa greater than air pressure
at nozzle.
Supply of water to mixing nozzle shall be such that a pressure of greater than 400 kPa or as dictated in the approved method statement can be
maintained.
b) Wet-mix process
Air compressors and delivery hose lines shall be of adequate capacity and size to provide a pressure of greater than 240 kPa at nozzle for 25
mm nozzles and proportionally greater for larger nozzles or as dictated in the approved method statement.

A12.5.7.1 Mix design
The Contractor shall submit details of the proposed shotcrete mix proportions prior to commencement of shotcrete activities for approval as per
Clause A12.5.4.2. Shotcrete operations shall only commence after approval of the mix design. The Contractor shall allow adequate programme-
time for design and approval of the shotcrete mix design. Mix ingredients and material source shall not be altered during construction without
the prior approval of the Engineer. Shotcrete shall be designed to yield a 28-day characteristic compressive strength as shown on the drawings
for different application areas or as specified in the Contract Documentation.
A12.5.7.2 Certification of skilled operators

Only experienced foremen, gunmen, nozzlemen and rodmen shall be employed, and satisfactory evidence of such experience shall be furnished
with the Engineer. Nozzlemen shall be highly skilled craftsman with demonstrable personal project history exceeding 4000 hours of spraying
concrete as the responsible nozzleman, or minimum 5 years’ referenced experience as responsible nozzleman. A nozzleman without
demonstrable practical experience as specified above shall be trained and certified as a nozzleman for the proposed shotcrete process and
proposed spraying orientation in accordance with the standards of, for example, the Shotcrete/ Sprayed Concrete Association (UK), American
Shotcrete Association, American Concrete Institute or other relevant certification authority approved by the Engineer.
Preconstruction trial panels

The Contractor shall provide trial panel formers made of nominal 20 mm thick shutter ply, size 600 mm by 900 mm skirted with reinforcement
as detailed in drawings, or where no reinforcement is required a light expanded metal mesh, standing at least 200 mm high around panel-
edges.
Where ultimate flexural strength requirements are specified, additional trial panels will be required.
Where energy absorption capacity is specified, specimen slabs constructed in accordance with EN14488 shall be required.
A12.5.7.3 Surface and slope preparation

All soil and rock to be covered with shotcrete shall be neatly trimmed manually where required and thoroughly cleaned with compressed air to
remove all loose fragments of rock and soil as required, the Contractor must make allowance for the Engineer to approach within 2,0 m of any
portion of area to be covered with shotcrete. Where soft material is to be covered with shotcrete, only obviously loose material shall be removed
and boulders shall be thoroughly cleaned with compressed air. The area of soft material shall be accurately graded to plan dimensions and
shall be thoroughly compacted, with sufficient moisture to provide a firm foundation to prevent absorption of water from the shotcrete, without
free surface-water. An initial layer of shotcrete with specified nominal thickness shall be applied to approved, clean areas of soft material with
minimum time delay. Irregular and rough rock contours, particularly rock surfaces resulting from drill and blast excavation techniques, may
require the application of an initial smoothening layer of shotcrete to a specified nominal thickness.
When shown on the drawings, joints, side formwork, headers, and shooting strips shall be provided for backing or panelling, stainless steel
gauging wires, spacers, inserts and profile boards shall be used where necessary to establish and control thicknesses, surface planes, and
finish lines during application of the shotcrete.

Geocomposite band drains shall be installed at the required locations as specified in the Contract Documentation and drawings prior to initial
shotcrete application. Groundwater seepage shall be collected in hoses, pipes or other drainage systems to prevent damage, and reduced
shotcrete quality.
A12.5.7.4 Formwork
Formwork and shooting strips for shotcrete shall be employed to ensure square corners, straight lines and a plane surface of shotcrete, except
as otherwise permitted by the drawings or the Engineer’s approval. Formwork and shooting strips shall be designed and placed to avoid pockets
of rebound.
A12.5.7.5 Fixing of reinforcement

Reinforcement shall be securely fixed over initial shotcrete layer/s by fastening to dowels and, where necessary, ties embedded in shotcrete via
gun nails, “n” bolts or other approved fixing systems.
Reinforcement shall be fixed so that it lies snugly against the initial shotcrete layer ensuring it will not vibrate during application of successive
shotcrete layers thereby ensuring voids are not formed between the shotcrete layers. Where sudden concave or convex surfaces preclude this,
the reinforcement may be cut so that smaller pieces can be formed into the curved surfaces. The minimum overlap of mesh reinforcement shall
be 150 mm, unless otherwise mandated by specific requirements of flexural or energy absorption reinforcement systems. Spacers shall be used
behind mesh where required and where no flashcoat has been placed.
The Contractor shall provide details of the fixing system he proposes to use to the Engineer one week prior to use. Improvements/ changes shall
be carried out during shotcreting as directed by the Engineer.

Shotcrete shall not be placed on a frozen surface or when ambient temperature is less than 5 degrees Celsius; nor shall it be placed when it is
anticipated that temperature during the following 24 hours will drop below 1 degree Celsius. Application of shotcrete shall be suspended if high
winds prevent proper application, or if rain occurs since this would wash out shotcrete mortar.
A12.5.7.7 Mixing and batching

Cement, aggregates, fibres, admixtures and approved additives shall be batched by mass to an accuracy of approximately 5 %.
For wet- and dry-mix spraying methods, the mixer shall be capable of achieving a uniform distribution of constituent materials. Mixing shall
continue until the mix exhibits a homogenous appearance, ensuring complete coating of fine aggregate particles with cementitious material and
for a period of more than 90 seconds thereafter. Special care shall be taken when adding fibres to ensure uniform dispersion.
Any mix spilled during handling or ejected from shotcreting equipment shall not be re-used. The mix shall be screened prior to gun-loading to
prevent inclusion of stones, cement bag scraps or other foreign materials. Prepared batches shall be discharged through the nozzle within 60
minutes of mixing.
A12.5.7.8 Delivery
a) Dry-mix process
Shotcrete shall be applied as dry as practicable to prevent shrinkage cracking, while ensuring a compacted dense homogeneous mass.
Appropriate measures shall be taken to ensure that fresh concrete remains sufficiently workable until end of spraying.
Dry mix compositions with moist aggregate shall normally be applied within 60 minutes after mixing and shall be discarded after such elapsed
period. If more than 60 minutes is required until the end of spraying of a batch, open time provided by the chosen measures shall be demonstrated
and verified in advance to the Engineer’s satisfaction.
Dry mix composition with oven or kiln dried aggregate may be stored for a limited time but shall be applied immediately after mixing with water.
Oven or kiln dried material should be pre-dampened before the nozzle or before it is loaded in the spraying machine. When adverse weather
conditions require use of quickset cement, procedures shall be adjusted to allow for limited open time of the mix.
Detrimental changes in the dry mix, such as segregation, or other changes shall be minimized during loading, transporting and unloading as well
as during conveying on site. Plant shall be chosen, screened off and suitably controlled in a manner that prevents excessive cement dust
generation and aggregate separation.
b) Wet-mix process
Measures shall be taken to ensure that mixed constituents remain sufficiently workable until end of spraying. Normal workability time shall be
determined by pre-construction tests on test panels. If work requires longer workability times it shall be verified by additional tests. Wet mix
compositions shall be applied within 60 minutes after mixing and shall be discarded after such elapsed period. Detrimental changes to the base
mix, such as segregation, bleeding, paste loss, or other changes shall be minimized during loading, transporting and unloading as well as when
being conveyed on site.
A12.5.7.9 Application of shotcrete

Mix temperature and consistency of shotcrete on site shall be monitored and controlled to ensure conformity before shotcreting. All adjustments
of the shotcrete stream through nozzle, whether air pressure, accelerator or shotcrete stream, shall only be performed when the nozzle is turned
away from the substrate. Shotcrete shall be composed and sprayed in a manner to limit rebound. Important factors influencing rebound, such as
concrete composition, nozzle angle and the distance to substrate, accelerator dosage, particular area of application, etc. shall be carefully
controlled and monitored on a continuous basis during application by competent Contractor supervisory staff.
The nozzle shall be directed, wherever possible, normal to the application surface, to produce a layer of optimum density and thickness, with full
encasement of reinforcement and minimum rebound. The distance between the nozzle and shotcrete surface is determined according to site
conditions and the possibility of obtaining good compaction, full encasement of reinforcement, and minimum rebound. For rock support normally
a distance of 1,0 m to 2,0 m is recommended, although site conditions may dictate an application distance outside this suggested range.
Thickness of each shotcrete layer depends on several parameters and shall be based on site conditions and composition of the mix. Specified
nominal shotcrete thickness may necessitate the application of two or more layers in order to avoid sagging and sloughing, particularly with
overhead work. Thickness of layers may be increased via use of admixtures such as accelerators; extenders such as silica fume, or the use rapid-
hardening cements.

A subsequent layer shall not be applied before the preceding layer is able to support it. Earlier applied shotcrete, should considerable time elapse
between placement of different layers to obtain specified nominal thickness, shall be cleaned either by blowing with compressed air, high pressure
washing, brushing or sand blasting and rewetted until suction of substrate, and consequent risk of an adverse influence on the subsequent
shotcrete layer, is mitigated, as approved by the Engineer.
All shotcrete shall be of a homogenous composition without any inclusion of rebound. Overspray and loose rebound material shall be removed
from surrounding areas and from substrate before shotcrete is applied to new or subsequent sections. Pre-wetted substrates shall be free from
running water.
When spraying on or through reinforcement, consequence of rebound and shadow effects shall be carefully taken into account and particular
attention given to minimize all possible negative effects. Mitigation measures may include ensuring that the air stream velocity around
reinforcement is sufficient and ensuring encapsulation of reinforcement is completed as soon as practical with adequate cover over reinforcement
and preventing poor compaction, if spraying with fibres onto other types of reinforcement.
A12.5.7.10 Finishing
The finished surface shall generally follow the contours of the roughly trimmed face such that it mimics the natural rock faces. It shall, however,
be free from rebound pockets or other defects. The inclusion of fibres may affect the finish obtained. The types of finish shall be designated on
the drawings by the following:
- SU: Undisturbed nozzle finish
- ST: Trowelled finish
- STB: Trowelled and brushed
- STF: Trowelled and flash-coated
- STW: Trowelled and wood floated.
The general procedure for achieving required finishes shall be:
Undisturbed nozzle finish (SU)
- The sprayed surface shall be brushed with a soft plasterer’s brush approximately one hour after placement to remove adhering rebound
dust and to prevent surface crazing.
Trowelled finish (ST)
- The surface shall be trowelled when the shotcrete exhibits initial set to obtain a uniform curved or plain surface true to line and shall then
be finished with one of the following treatments if so specified:
Brush-coated (STB)
- Coating of the trowelled surface with a cement mortar slurry using a soft broom or brush to give a soft “brushed effect”
Flash-coated (STF)
- Coating the trowelled surface with a thin uniform layer approximately 3,0 mm thick of shotcrete at least four hours after trowelling but not
later than eight hours.
Wood-floated (STW)
- Floating the trowelled surface with a wood float to produce a smooth even surface free from trowel marks
A12.5.7.11 Rebound material

Rebound material shall not be re-used. Rebound material shall be removed from all future working areas and may not be covered up by
subsequent applications of shotcrete. It shall also be cleaned from the surface of any finished work. Where coarse aggregate >10 mm is used,
higher rebound volumes are anticipated. There may be an increased proportion of fibres in rebound when fibres are used. Appropriate correction
to mix design will be required.
A12.5.7.12 Properties of hardened shotcrete

a) Compressive strength
For the purpose of determining compressive strength, characteristic cylinder strength, determined from cores extracted from test panels, using 75
mm diameter, 150 mm high cylinders prepared strictly in accordance with SANS 3001-CO2-2 and tested in accordance with SANS 3001-CO2-3
at a sample age of 28 days. Compressive strength classes shall conform to Table A14.6.7-1 of Chapter 14. For particular uses, it may be
necessary to specify compressive strength at ages earlier or later than 28 days, or after storage under special conditions. In assessing strength,
other sizes of specimens and other curing regimes may be used provided that relationship to those standardised is established and documented.
b) Flexural strength
Ultimate flexural strength shall be determined from beam specimens cut from test panels, tested at 28 days in accordance with SANS 5864.
c) Energy absorption capacity
Energy absorption capacity shall be determined from a test panel slab specimen, tested at 28 days, in accordance with EN 14488-5, and shall
conform to specified energy absorption class defined in Table A14.6.7-2 of Chapter 14.
A12.5.7.13 Construction joints

Once a section of work has commenced, the application of shotcrete shall be continuous up to the construction joints shown on the drawings or
up to approved locations. All construction joints shall be standard feathered type joints, for last mix of the day the shotcrete layer shall be tapered
to a fine edge which shall be wet and cleaned with an air or water blast before joining the following day’s work.
Irregular edges shall be cut back to straight lines before commencing with further work.

A12.5.7.14 Weepholes
Weepholes comprising nominal 50 mm diameter U-PVC piping shall be installed at those positions indicated on the drawings or as otherwise
Engineer-instructed. Pipes shall protrude 20 mm beyond the surface of final shotcrete layer and have their inner end wrapped with a single layer
of geosynthetic. Weepholes shall be positioned to intersect seepage anticipated from soft zones or fixed in position to butt against angled or
vertical geosynthetic band drains. Weepholes shall be positioned prior to application of initial shotcrete layer with the geosynthetic end hard
against substrate face.
Outer ends of the pipes shall be adequately protected during application of shotcrete. Protective plugs shall be removed after spraying and pipe
checked to ensure no shotcrete material entered any of the weepholes.
A12.5.7.15 Control test panels

The Contractor shall produce control test panels, fully complying with requirements of the preconstruction trial panels, alongside every new stage
of the work. A minimum of one control test panel required per lot of shotcrete, and at least one per day. At the start of or during work, nozzle
operator shall produce test panels alongside and in similar orientation to the work. These test panels shall be protected and cured in the same
manner as the work.
A12.5.7.16 Edge detail of shotcrete

Details of finishing off shotcrete at the brow and edges shall be indicated on drawings. Methods to terminate shotcrete at the perimeter shall
prevent surface water from undermining the shotcrete. For tender purposes, allowance shall be made for trench excavation along the perimeter
with nominal dimensions of 0,5 m wide and 0,5 m deep or as indicated on the drawings, in order to allow for the finishing off of shotcrete at the
edges
Where boulders or suitable quality rock outcrop occur at a cut-brow, no cut off may be required, if Engineer-instructed, and shotcrete shall be
neatly stopped at rock surface -top.
Where specified on drawings, shotcrete shall be terminated to facilitate incorporation of precast coping units.
A12.5.7.17 Aesthetic appearance

The Contractor shall take due care in assessing variation in texture and colouring of natural adjacent rock and soil slopes. Finish of all permanently
visible shotcrete surfaces shall be in harmony with surrounding environment.
The Contractor shall pay particular attention during application of shotcrete to carefully control desired variations in colouring and texture of
shotcrete to suit the natural local environment. Colour pigmentation shall be agreed in collaboration with, and approval of the Engineer via trial
colour panels. In some locations, the Engineer may instruct the formation of planting boxes in which vegetation may be planted. Where so required
details shall be given in the Contract Documentation.
A12.5.7.18 Protection of adjacent work

During the shotcreting progress, where appearance is important, adjacent facilities or structures which may be permanently discoloured, stained,
or otherwise damaged by overspray, dust or rebound, shall be adequately protected and, if contacted, shall be cleaned at the Contractor’s cost
by early scraping, brushing, or washing, as surroundings permit.
A12.5.7.19 Blasting restriction

In order to prevent damage to shotcrete, no blasting shall be carried out within 50 m of a shotcrete section within 72 hours of shotcrete-
application. The total explosive charge detonated instantaneously shall be such that Peak Particle Velocity (PPV) less than 50 mm/s. All
completed works shall be inspected after any blasting within 100 m of the shotcreted area.
A12.5.7.20 Protection and curing

a) Protection from adverse environmental conditions
Refer to Clause A14.6.7.17a) of Chapter 14.
b) Curing
Refer to Clause A14.6.7.17b) of Chapter 14.
A12.5.8 WORKMANSHIP
The tolerances provided below shall be maximum permissible deviations from specified dimensions, levels, alignment, positions, etc., as shown
on drawings.
- Position: the lesser of 100 mm or the specified position of the total shotcrete member.
- Thickness - Arithmetic mean value per lot: minimum 100 % of specified layer thickness, maximum thickness not specified.
- Individual depth at any measurement point: minimum 80 % of specified layer thickness, maximum thickness not specified.
- Surface regularity (where applicable): maximum value of any individual irregularity, measured with a custom template that ensures specified layer
thickness is achieved and is less than 25 mm.
A12.5.8.2 Acceptance criteria

Routine inspection and quality control shall be performed by the Contractor or Engineer as specified in clauses A1.2.8.1 and A1.2.8.2 of Chapter
1. Compressive strength shall be determined using cored cylinder specimens prepared in accordance with SANS 3001-CO2-2 and tested in
accordance with SANS 3001-CO2-3 at the age of 28 days.

Ultimate flexural strength shall be determined from beam specimens prepared from test panels and tested at 28 days in accordance with SANS
3001-CO2-5.
Criteria for compliance with requirements specified for 28-day characteristic compressive and ultimate flexural strength shall be as specified in
Clause A20 1.7.5d) (Plan B) of Chapter 20.
The Contractor’s attention is drawn to Clause A1.2.8.1 of Chapter 1: Process quality control.
A12.5.8.3 Procedure in event of non-compliance with requirements

Any lot represented by test cores failing to comply with the criteria specified above for characteristic strength shall be rejected.
The Contractor, in all cases where shotcrete as supplied fails to comply with requirements, shall immediately take required remedial action by
changing mix proportions to obtain required strength.
A12.5.8.4 Special tests ordered by Engineer

The Engineer may order the Contractor to have concrete cores, flexural beams and or energy absorption slabs, which were prepared under
direction of the Engineer, tested at an approved testing laboratory, in which case payment will be made for such tests in accordance with
provisions of Section C20.1 of Chapter 20.

B12.5 SHOTCRETE
CONTENTS
B12.5.1 SCOPE
B12.5.2 DEFINITIONS
B12.5.3 GENERAL
B12.5.5 MATERIALS
B12.5.8 WORKMANSHIP
B12.5.1 SCOPE
B12.5.2 DEFINITIONS
B12.5.3 GENERAL

B12.5.5 MATERIALS


B12.5.8 WORKMANSHIP

C12.5 SHOTCRETE
(i) Preamble
pay items.
C12.5.1 Establishment on site lump sum
The tendered lump sum shall include full compensation for establishing on site all plant and equipment, scaffolding, platforms, materials and
personnel necessary to carry out the specified work and for the removal from site of all such plant and equipment including all temporary works
such as access roads, staging, platforms and such like on completion of the works.
Work shall be paid as Lump Sum, 50 % of which will be due when all equipment is on site, trials (if any) are completed, and the first production
shotcrete has been applied to full thickness as specified. A second instalment of 25 % shall be payable after half the shotcreting has been
completed and final 25 % after all the shotcrete has been applied - and accepted - and all equipment and plant removed from site
C12.5.2 Surface preparation for shotcreting square metre (m2)
The unit of measurement shall be the square metre of face/slope cleared of all loose or unwanted material, including indicated vegetation, and
manually trimmed to designed lines and levels as specified.

The tendered rate shall include full compensation for trimming all material, and for all equipment, labour and other incidentals necessary to
complete the specified work.
C12.5.3 Supply and installation of reinforcement:
C12.5.3.1 Welded steel mesh fabric (Ref. 395) square metre (m2)
C12.5.3.2 Fibre (type indicated kilogram (kg)
C12.5.3.3 Other special reinforcement systems as specified square metre (m2)
The unit of measurement for steel mesh shall be the net square metre of reinforcement actually incorporated into shotcrete. Measurement shall
be based on square metre of soil and or rock slope covered with mesh and measured on the plane of the slope. No overlaps of mesh and or
reinforcement system shall be measured.
The unit of measure for fibre shall be the mass in kilograms of fibre actually used, as determined by the kilogram of fibre per cubic metre of
shotcrete specified.
The tendered rate shall include full compensation for supply and installation, including all equipment, plant, materials, labour and incidentals
necessary to carry out the specified work and including specifically supply and installation of pins, earth spikes, soil nails/ rockbolts, wire ties, gun
nails and any other approved fastenings for the completion of the work as specified.
C12.5.4 Shotcrete (of specified thickness or volume):
C12.5.4.1 Flash/base coat (unreinforced) (specify thickness) square metre (m2)
C12.5.4.2 Intermediate coat/s (specify thickness and number of layers) square metre (m2)
C12.5.4.3 Final coat (specify thickness, pigmentation and finish square metre (m2)
C12.5.4.4 Dental shotcrete square metre (m2)
The unit of measurement shall be the net square metre of face measured in the plane of the cutting face, which is protected by shotcrete of
specified nominal thickness, installed as specified. No separate allowance shall be made for an uneven surface when measuring the area over
which shotcrete is applied.
The unit of measurement for dental shotcrete shall be the cubic metre of shotcrete of measured batch volume, agreed with the Engineer and
installed in accordance with the specifications.
The tendered rate shall include for everything necessary to carry out specified work as specified. and shall include safe access for the Engineer
to any portion of the cut face or slope.
C12.5.5 Removal to spoil of material trimmed from slope cubic metre - km (m3.km)
The unit of measurement shall be the cubic metre - kilometre which is calculated as the product of the quantity of material cleared, temporarily
stockpiled, loaded, transported in excess of 1.0 kilometre and disposed at approved spoil site, in accordance with the requirements multiplied by
the applicable haul distance which shall be calculated as defined in Clause A1.7.3.1 of Chapter 1.
The tendered rate shall include full compensation for trimming all material, and for all equipment, labour and other incidentals necessary to
complete specified work. Haul distance shall be measured from mass-centre to mass-centre.
The volume of such material shall be taken to be equal to 70 % of the loose struck volume measured in the truck.
C12.5.6 Edge finishing of shotcrete metre (m)
The unit of measurement shall be the linear metre of perimeter where shotcrete is required to be finished off as detailed in the drawings, all as
specified.
The tendered rate shall include full compensation for excavation and spoiling of material from trenches, bending of mesh or reinforcement,
application of shotcrete irrespective of volume involved as well as all equipment, labour, transport and other incidentals necessary to complete
the specified work.
C12.5.7 Geopipe collectors and weepholes:
C12.5.7.1 50 mm diameter U-PVC weephole piping (specify length and class) number (No)
C12.5.7.2 Geopipe collectors (specify type, diameter and class) metre (m)
C12.5.7.3 Other piping (specify type, diameter and class metre (m)

The unit of measurement for the U-PVC weephole piping shall be the number of weepholes installed. Unit of measurement of the geopipe
collectors and other pipes shall be the metre length installed.
The tendered rate shall include full compensation for supply, installation, protection during shotcreting, geosynthetic wrapping, plant, equipment,
labour and all other incidentals necessary to complete the specified work.
C12.5.8 Geocomposite/geosynthetic drain as specified metre (m)
The unit of measurement shall be the linear metre of geocomposite drain installed as specified at spacings or positions specified or as indicated
on the drawings.
The tendered rate shall include full compensation for supply, installation, protection during spraying, plant, equipment, labour and all other
incidentals necessary to complete the specified work.

D12.5 SHOTCRETE
The Contractor shall provide detail b ed specifications and certificates from independent reputable agencies for all proprietary casing/sleeves and
CONTENTS
D12.5.1 SCOPE
D12.5.2 GENERAL
D12.5.1 SCOPE
D12.5.2 GENERAL
published instructions.

- Materials and Materials Design as per Clause A12.6.3.
- Materials as per Clause A12.6.5,






12.6 MECHANICALLY STABILISED EARTH AND GABIONS
CONTENTS
A12.6.1 SCOPE
A12.6.2 DEFINITIONS
A12.6.3 GENERAL
A12.6.5 MATERIALS
A12.6.8 WORKMANSHIP

A12.6 MECHNICALLY STABILISED EARTH AND GABIONS

A12.6.1 SCOPE
Mechanically Stabilised Fill (MSE) incorporates reinforced earth walls with a variety of possible facings and reinforced earth slopes. These
are designed to SANS 8006. Reinforcement may be metallic in the form of strips, grids or meshes or polymeric in the form of strips,
geotextiles, geogrids or meshes. Facings may be wrap-around, concrete, concrete blocks, steel or mesh.
Gabions include boxes filled with approved rock generally used for the construction of gabion walls (mass gravity structures) and mattresses
which are generally used as single layer aprons only in revetments, channel linings, etc. This Section covers the construction of gabion
walls, -aprons and -mattresses for constructing minor non-structural retaining walls, lining channels, revetments and other anti-erosion and
containment structures.
A12.6.2 DEFINITIONS
Anchored earth - is a form of reinforced soil which uses anchors embedded within the soil mass to provide stability/resistance to pull-out
by passive action of the anchor and friction along the anchor shaft or loop.
Axially-flexible reinforcement - is reinforcement that can absorb tensile loads only.
Axially-stiff reinforcement - is reinforcement that can absorb tensile, shear and bending loads.
Extensible reinforcement - is reinforcement that sustains design loads at strains greater than 1 %.
Geogrids - are polymeric, planar structures consisting of an open network of connected tensile elements used in geotechnical and civil
Engineering applications.
Geotextile - are permeable, polymeric materials, which can be woven, non-woven or knitted, used in geotechnical and civil Engineering
applications.
Inextensible reinforcement - is reinforcement that sustains design loads at strains less than or equal to 1 %.
Partial factors - partial factors are specific design parameters to account for uncertainty.
Polymeric reinforcement - is a generic term that encompasses geosynthetic materials used as soil reinforcement in geotechnical
Engineering such as geotextiles, geogrids and geostrips.
Reinforced soil - is a general term which refers to use of imported or in situ soil or other material in which tensile reinforcements act through
interface friction, bearing or other means to improve stability.
Reinforced soil segmental block structure - is a reinforced soil structure with a facing comprising dry stacked blocks with a fixed
connection, without compressible joints between blocks and without joint fillers/covers.
Reinforcement base strength - is the un-factored strength of reinforcement at end of its design life.
Reinforcement design strength - is the factored strength of reinforcement at end of its selected design life; it is the reinforcement base
strength divided by the appropriate partial material factor.

Retained backfill - is the fill material located between the reinforced mass and natural soil.
Gabion boxes - are made from double twisted steel mesh and are subdivided into 1,0 m wide cells by diaphragms at 1,0 m intervals.
Gabions are filled with selected rock material providing pervious, semiflexible building blocks for slope and channel stabilisation.
Gabion mattresses - are made from steel mesh and are subdivided into 0,6 or 1,0 m metre wide cells by diaphragms. The mattresses are
filled with selected rock material providing pervious, channel linings, revetments and other anti-erosion and containment structures.
A12.6.3 GENERAL
A12.6.3.1 Design of Mechanically Stabilised Earth (MSE)
Table A12.6.3-1 below illustrates design considerations for vertical MSE’ walls illustrating typical design height limitations and uses. All geogrid or
strip reinforcement shall have a positive mechanical structural connection when used to retain a road pavement (surfacing, structural layers, kerbs,
etc) or a structure. The structural adequacy and pullout capacity of the connections shall be demonstrated by test data from pullout tests. Durability
and deflection of welded wire or gabion facings shall be crucial in assessing if the system can be used in the specific application.
Table A12.6.3-1: Design Considerations for Vertical MSE height limitations:
Type Description Typical Requirements Comments
Height
Limitations
(m)
Precast Concrete Discrete panels with 0 -18 m
Panel System compressible
bearing pads placed
between joints
Closed block Positively reinforced 0 -12 m ASTM D6638 and ASTM D6915 test results These systems
Segmental Block concrete segmental must be provided for acceptance of the shall have a
Retaining Walls I block retaining walls system. “positive”
connection to the
facing when
retaining road-
pavements or
structures.
MSE Wire-Faced Welded steel 0 -10 m Durability must be assessed in accordance to Not recommended
facings EN ISO 9223 and 9224 and the working life for bridge
provided. The expected deflection of the abutments
facing should be assessed and commented
on in the design.
Gabion Faced Reinforced Gabion 0 -10 m Durability must be assessed in accordance to Not recommended
faced wall EN ISO 9223 and 9224 and the working life for bridge
provided. The expected deflection of the abutments
facing should be assessed and commented
on in the design.


and shall be subject to the approval of the Engineer. The Contractor shall submit product certificates, conformance documentation (as per Part D)

of the works:
Clause Requirements* Period prior to use
A12.6.4 Materials Design Approvals 2 weeks prior to use
Materials Approvals
A12.6.5.1a) Materials for MSE wall elements, gabions 2 weeks prior to use
A12.6.5.2a) Reinforcement for MSE walls 2 weeks prior to use
A12.6.5.12 Testing of joints 2 weeks post construction
Construction Method Approvals

A12.6.3.1 Detailed method statements 4 weeks before construction
A method statement providing details of operation- Prior to placing reinforcing
A12.6.7.2c)
sequence elements/gabions

A12.6.4.1 General
MSE systems are designed to SANS 8006-1. The design of MSE systems covers both the internal and external stability.
Alternative designs submitted by the Contractor shall cover both internal and external stability and shall be vetted by the Engineer. Due
allowance shall be made in his programme for such review and no extension of time will be allowed in this regard.
The Contractor shall, unless otherwise specified in the Contract Documentation, be responsible for the design of all concrete, grout,
bentonite, and shotcrete mixes required to carry out the works as specified.
Where the execution of any specialised technique is required, the Contractor shall take all the aspects given below into consideration. It
should be noted that all facings, soil reinforcement and fastener materials shall be designed and sourced from a single MSE supplier to
ensure compatibility.
Where applicable, the following shall be specified by the Engineer in the Contract Documentation, but not necessarily limited to:
- Material type and quality,
- Limits of areas and depths to be treated,
- Concrete mix design,
- Reinforced concrete strength, facing characteristics, post-treatment properties, durability and any other deliverables as may be appropriate,
- Layout of lateral support,
- Sequence of installation,
- Permissible limits and tolerances,
- Measurable properties to be achieved over the life span of project,
- Anti-corrosion requirements,
- Environmental and safety requirements specific to the techniques to be executed,

The following site information will generally be provided by the Engineer:
- Definition of objectives and control criteria,
Notwithstanding the items listed above, it remains the Contractor’s obligation to ensure that all necessary information required, is procured and
considered.
- Finishing off of treatment areas to specified lines and levels, whether materials are to be removed, removed and replaced by other materials,
processing of materials and all other measures to be carried out in meeting requirements as specified in the Contract Documentation.
- Contractor shall provide a quality management plan indicating his proposed quality assurance testing programme which shall allow, if necessary,
testing at each treatment position as required. Testing methods to be employed shall be as specified in Contract Documentation.
A12.6.5 MATERIALS
A12.6.5.1 Materials for MSE walls
a) General
All materials used in constructing MSE walls, shall comply with Table B.1 of. SANS 54475 and be subject to approval by the Engineer. When
requested by the Engineer, the Contractor shall submit test certificates from an approved independent testing authority to show that materials
comply with specified requirements, or where applicable certificates from patent holders or licensees certifying that manufactured items comply in
all respects with relevant product specifications. All facings, soil reinforcement and fastener materials shall be designed and sourced from a single
MSE supplier to ensure compatibility.
b) Concrete facings
Concrete facings shall be manufactured from materials which comply with relevant requirements of Sections A13.2, A13.3 and A13.4 of Chapter
13 and have a 28-day cube strength of 30 MPa unless otherwise detailed in the Contract Documentation.
c) Concrete block facings
Concrete block facings used in MSE walls shall be manufactured and tested according to SANS 508. These shall have a positive connection to
reinforcement.
Pigments used for colouration of concrete blocks shall conform to BS EN 12878.
d) Concrete bases and foundations for earth retaining systems
All materials for concrete bases and foundations for earth retaining systems shall comply with relevant requirements of Sections A13.3 and A13.4
of Chapter 13.
e) Metallic soil reinforcements
Metallic soil reinforcement shall be manufactured from corrosion-resistant materials designed to ensure adequate performance when buried for
the design life of the structure. This metallic reinforcement may take the form of sheets, grids, meshes, strips, bars, rods, ladders etc. and shall
comply with section 3.2.1 of BS 8006-1:2010.
Galvanizing shall comply with the requirements of SANS 121 for bars and SANS 675 for wire up to 5,0 mm in diameter.
f) All facing units and their applications shall conform to SANS 54475 Fasteners between facing and reinforcing elements
Fasteners or joints (either metallic or polymeric) between facing and reinforcing elements shall comply with Section 3.4 of SANS 8006-1). Facings
shall have a positive connection to reinforcing elements. Galvanising shall comply with SANS 121.
g) Joint filler materials on facings
Fillers shall be durable, flexible, and resistant to effects of air pollution, and water that might be contaminated with de-icing salt.
h) Bedding material
Selection of bedding material depends upon structural behaviour of the facing assumed in design of the wall. Cement mortar or a durable gasket
material such as resin bonded cork, bitumen bonded cork, rubber or ethylene propylene diene monomer (EPDM) may be used.
i) Sealing material
Filling of joints other than bedding joints may be done either with closed cell polyethylene foam, closed cell polyurethane foam strips in the joint, or
geotextile strips over the rear face of joint as approved by the Engineer.
Any accessory proprietary products, elements or fittings necessary for construction of MSE structures shall comply with appropriate, accepted
standards or specifications.
j) Polymeric materials
All polymeric materials delivered to a site shall be identified in accordance with BS EN ISO 10320 and SATR 20432.

k) Fill Materials
Selected fill behind MSE wall facings over the length of reinforcement shall comply with requirements of a G5A material as given in Table A4.1.5-
4 of Chapter 4 with a maximum size of 50 mm and be free draining.
l) Polymeric reinforcement joints
(i) General
Joints are subdivided into prefabricated joints and joints made during execution of the works. A number of different jointing systems are
in use.
Joints in geotextiles shall normally be sewn where load transference is required utilising either single or double chain stitching. Types of
stitching and seams (prayer, butterfly, J, flat or Z) for geotextiles and bodkin details for polymeric meshes or grids are given in the Contract
Documentation.
Care shall be taken to ensure that:
- Bodkins are of sufficient cross-sectional area and strength to avoid excessive deformation,
- Bodkins are not so large as to distort theparent material causing stress concentrations, or
- Joints are pre-tensioned prior to loading, to reduce joint displacement as components lock together.
Joints shall be formed to have high mechanical and durability efficiency, compared to the performance characteristics of the parent
materials. Test methods used to assess joints shall correspond closely to those procedures employed when determining properties of the
parent materials. All joints used in permanent structures designed to carry loads shall be tested in accordance with BS EN ISO 10321
and results presented to the Engineer for approval.
(ii) Overlaps
In situations where relatively small tensions develop, overlapping may be employed utilising coarse sand-filled 20 mm thick joints (Sand
as per Table A3.1.5-1 of Chapter 3.
Such joints are sometimes used in secondary tensile directions but shall not be employed in primary tensile directions in reinforced soil
structures. Overlapping may also be used for jointing under water where amount of overlap depends on design considerations and
construction conditions.
(iii) Stapling
This method may be used with geotextiles to make temporary joints. Stapling shall never be used for structural jointing.
(iv) Other jointing methods
Other jointing methods may be adopted. However, general recommendations as set out above still apply.
m) Fasteners and connections between facing and reinforcing elements
(i) General
Fasteners are used to make a connection between the reinforcement and the facing and take the form of dowels, rods, hexagon headed
screws and nuts and bolts, and shall consist of either steel or polymers.
The choice of material used to form the fastener shall be compatible with design life of structure. Materials for fasteners and
connections shall conform to criteria described in BS EN 14475
(ii) Steel coatings
These may be divided into two groups:
- metallic coatings, including galvanizing in accordance with BS EN ISO 1461/SANS121 and aluminium-zinc coatings in accordance
with BS 2569; and,
- organic coatings, including bitumen in accordance with BS 3416 and BS 4147, coal tar products in accordance with BS 4164, polyvinyl
chloride (PVC), liquid and powder epoxies and liquid polyurethanes.
The application rates of coating to the base metal of the fastener are given in the Contract Documentation.
A12.6.5.2 Materials for gabions

a) General
The specifications cover all the materials as placed and/or processed in its final position within the road reserve.
It is the Contractor’s responsibility to ensure that the materials delivered to site the road shall meet these specified requirements.
b) Rock
Rock used as filling for gabion boxes or mattresses shall be clean, angular, hard unweathered and durable boulders, rock fragments or crushed
rock. Rounded alluvial cobbles/boulders shall not be used. Rock containing aggressive minerals such as sodium oxide or calcium oxide shall not
be used unless suitable corrosion resistant wire coatings are used. No rock fragment shall exceed the maximum size given in Table A12.6.5-1,
and at least 85 % of the rocks shall be of a size equal to or above the average least dimension given.

Table A12.6.5-1: Rock requirements for gabions
Rock size
Nominal depth of mattress* or
Nominal size of mesh (average (largest dimension)
gabion box(**)
least dimension) [mm]
[m]
[mm] Average least dimension
Maximum size mm
(ALD) (mm)
0,17*/ 0,23* 60 80 120
0,3* 60 80 150
0,5** 80 100 250
1,0** 80 100 250
c) Wire
All wire used and dimensions for manufacturing the gabions and for tying during the construction of the gabions shall comply with the requirements
of SANS 675 for class A heavy galvanized mild-steel wire.
d) Polymer coated wire

Gabions of PVC-coated mesh and binding wire shall comply with the requirements of SANS 1580 and that with Nylon coatings shall comply with
the requirements of EN 10245-5.
e) Galvanizing
All wire used in the making of gabions shall comply with SANS 1580 (zinc) or SANS 10244-2 table 2 (Zn95Al5).
f) Wire mesh
Wire mesh shall comply with the requirements of SANS 1580.
g) Box and mattress sizes

Standard sizes of boxes and mattresses are as follows:
Boxes:
Length: 1, 2, 3 or 4 m
Width: 1,0 m
Depth: 0,5 m and 1,0 m
Diaphragm spacing: 1,0 m
Mattresses
Length: 2, 3 or 6 m
Width: 2,0 m
Depth: 0,17 m, 0,23 m and 0,3 m
Diaphragm spacing: 1,0 m
Other gabion sizes may be supplied, subject to the Engineer's prior approval.
h) Geotextile behind and below the gabions

Geotextile shall comply with the specified requirements.
i) Alternative materials
Alternative materials required, their property requirements, construction, measurement and payment shall be specified in the Contract
Documentation.

Normal earthmoving and compaction equipment may be used in construction of MSE walls and slopes except for the proviso that no compaction
equipment of mass greater than 1 500 kg may be used within 2,0 m of facings. This area shall be compacted with pedestrian rollers and
mechanical thumpers.
For gabions construction the Contractor shall provide a comprehensive equipment list for the installation of the gabions as well as for the ancillary
works such as the construction of foundation trenches and for the surface preparation for bedding the gabions in his method statement for this
work.

A12.6.7.1 MSE walls and slopes
a) General
All MSE walls constructed with concrete block facings (CBRW) shall be installed as per the Concrete Block Retaining Wall Installation Manual 5th
edition 2009 and SANS 54475.
All MSE walls constructed with concrete facings shall be constructed in accordance with SANS 54475.
b) MSE walls with concrete facings
(i) Concrete facings
Concrete facings shall be manufactured in accordance with the dimensions and details shown on the MSE wall supplier’s drawings
and where necessary, these details shall be adapted to suit joining onto existing structures, inclined foundations, varying heights or
similar conditions. Special facings shall be produced for copings, and terminal sections. The 28 day compressive strength of the
concrete shall be 35 MPa unless otherwise specified in the Contract Documentation.
These facings shall be manufactured in accordance with the provisions of Sections A13.2, A13.3 and A13.4 of Chapter 13 with due
regard to cover, durability considerations and alkali silica reaction. They shall have an off-shutter class F2 surface finish. Concrete
facings are typically between 140 and 180 mm thick. Where specified in the Contract Documentation, selected facings shall have a
protruding patterned or exposed aggregate finish.
Date of manufacture and classification of every facing panel shall be clearly marked on the back of such panel at the top end.
Concrete facing panels shall not be removed from their moulds until the concrete attains a cube compressive strength of 7 MPa. They
shall not be stacked more than five high during storage. Bottom concrete facing panels shall be supported off-ground via timber
blocking and adjacent concrete facing panels shall be separated by timber blocks packed between the tie strips to prevent any forces
from being transmitted onto the tie strips.
(ii) Metallic reinforcement
1. Handling
Metallic reinforcement shall be loaded, unloaded and handled in such a way as to prevent bending which causes permanent set
or damage to any protective coating.
Reinforcement shall not be dragged across abrasive surfaces such as reinforced concrete or coarse angular soils or through
deleterious materials.
To avoid punctures or fractures in any covering that might allow ingress of corrosive media, only fibre rope, webbing slings or
protected chains shall be used.
Connecting lugs attached to the facing elements shall be handled with similar care to prevent damage to the protective covering.
2. Storage
Metallic reinforcement shall be stored in neat stacks clear of ground at all times and supported on non-absorbent materials to
avoid contamination. Ideally storage shall be located close to construction activities. Items of different lengths and cross-sectional
dimensions shall be stacked separately and clearly marked.
Storage arrangements shall preferably maintain separation between batches delivered. Ideally one batch shall be fully utilised
before the next one is used to facilitate quality control.
(iii) Polymeric reinforcement
1. General
Polymeric reinforcements are woven, knitted, coated or extruded geotextiles, geogrids or geocomposite geotextiles. Polymeric
reinforcements shall be assessed according to SATR 20432. Details of packaging and hence handling and storage thus vary
from product to product. The manufacturer’s prescriptions to this effect shall be strictly adhered to.
Where recommendations given below do not relate to a particular product further advice shall be sought from an approving
authority, supplier or manufacturer.
2. Handling
Polymeric reinforcement materials are generally supplied in rolls, which shall bear a conformity identification mark, e.g. according
to BS EN ISO 10320. Site handling shall ensure that surface abrasion, slitting, notching or tearing is prevented.
Where a central tube or mandrel to facilitate lifting is supplied, the manufacturer’s recommendations shall be followed. In any
case, geotextiles supplied in rolls shall be supported at a minimum of two points to prevent excessive bending unless a central
steel tube is used for support.
3. Storage
Storage condition of geosynthetic reinforcing materials shall take account of their characteristics and placement needs.
Generally, short term storage on site may be carried out without particular precautions as long as products are kept within their
packaging. Prolonged exposure to light shall be prevented either by storage under cover or by opaque-packaging cover.
Geotextiles shall be stored in dry conditions particularly for materials that absorb water and where low temperatures might cause
freezing and make placing difficult.
Where bars or other fixings are required for geosynthetic reinforcement, these shall be stored in clean dry conditions.

(iv) Accessories
Any accessory proprietary products, elements or fittings shall be manufactured in accordance with the dimensions and details shown
on the drawings. Accessories shall be handled in accordance with the supplier’s recommendations.
c) Construction
(i) Excavations
All excavation for bases of earth retaining systems shall be in accordance with the provisions of Section A13.1 of Chapter 13. The
Contractor shall not commence with construction of the bases before the excavations are properly cleaned by him and inspected and
(ii) Foundation
Foundation planes for MSE structures shall be graded for a width equal to length of soil reinforcement and to heights shown on the
MSEW drawings and compacted to greater than 95 % of the Maximum Dry Density as per SANS 3001 in accordance with the
requirements of Clause A5.1.8 of Chapter 5 or such higher density as may be specified. All foundation soils found to be unsuitable
shall be removed and replaced with compacted, approved granular material or other such materials as are approved by the MSE
supplier’s Engineers. Measurement and payment for this work will be paid for under the relevant items of Chapter 5. Alternatively,
such preparation preceding foundation construction, as may be specified in the Contract Documentation, shall be carried out in
accordance with the provisions of other sections of Chapter 12.
A concrete footing, conforming to correct lines and levels, shall be constructed in accordance with details shown on the MSE drawings.
(iii) MSE
Prior to the placing reinforcing elements a method statement shall be submitted to the Engineer for approval providing details of
operation-sequence. The method adopted shall ensure the reinforcement does not suffer deterioration during placing and any joints
or connections are effectively- formed.
Construction of MSE shall conform to SANS 54475 and any procedures specified by wall system supplier as agreed with the Engineer.
Concrete facing panels may be installed at the Contractor’s risk when cube strength is greater than18MPa. Testing in this regard
shall conform to the requirements of Clause A20.1.7.5d) of Chapter 20 for concrete strengths.
The following specifications are considered as minimum construction requirements (In all cases the MSE supplier’s Engineering
specifications shall prevail if they exceed minimum construction requirements):
- The bottom row of facing panels shall be carefully aligned on the foundation footings in accordance with the details provided on
the approved construction drawings. These facing panels shall be properly braced to prevent movement during placing of the
first layers of back-fill. Each facing panel shall be individually checked by survey after placement to confirm it is correctly placed
to line, levels, inclinations and tolerances specified.
- Geosynthetic/polymer reinforcement shall either be fixed to the panels providing positive connection in an approved manner or
clamped between the panels where specified. Special care shall be taken to ensure the edges on facing panels are not sharp
or jagged such that thereinforcement may be damaged.
- The geosynthetic layer shall be uniformly laid taut over its specified length and held in place by approved means. The Engineer’s
approval of such tensioning shall be obtained prior to any placement of backfill. There shall be no loss of tension during
backfilling operations. Damaged reinforcements shall be removed and replaced at the Contractor’s cost.
- Fill material behind the facing panels shall be placed and compacted in accordance with Chapter 4 to greater than 95 % of the
Maximum Dry Density as per SANS 3001 at a moisture content of 0 to plus 2 % of the optimum moisture content, except that
the layer thickness may vary slightly to suit the position of soil reinforcement.
- Deposition, spreading, levelling and compaction of fill shall generally be carried out in a direction parallel to the facings, and
shall be executed in stages to alternate with placing and fixing of the reinforcing elements and the facing.
- Fill shall be deposited, spread, levelled and compacted in horizontal layers of appropriate/specified thickness. Spreading and
compaction shall be carried out so that all layers of the soil reinforcing elements are fixed at the specified levels on top of the
compacted fill.
- Fill shall be placed such that it slopes away from the face at 2 % to ensure water ponding at the soil/facing element interface
does not occur.
- Fill shall not be placed right up to the cladding panels before the underlying reinforcing is covered, with compacted fill materials
to anchor the reinforcement adequately to maintain the facing panel in position. Fill shall be placed from the end of the
reinforcement to the cladding panels.
- Metallic reinforcement shall be placed on compacted fill and in intimate contact with the ground, which shall have a nominal fall
of 2 % away from the facing.
- If inspection of elements prior to or during placement reveals bends or kinks with a radius less than twice the reinforcement
thickness, these shall be rejected.
- Small areas of galvanized coating damaged during handling shall be repaired in accordance with BS EN ISO 1461.
- Most sheet products exhibit preferential strength direction and therefore placing of reinforcement shall be consistent with the
direction of major stresses. Details shall be indicated on the drawings and Contract Documentation.
- Ideally strips shall be laid in the major load bearing direction, i.e. transverse to the embankment centreline. However,
construction is facilitated and sewing time minimized if geosynthetics are laid in centreline direction. This is not recommended
but may be allowed if joint-integrity is assured and the design takes account of likely transverse-direction-reduced-strength.
- Geotextiles and geogrids are generally supplied in rolls of specific width. Rolls shall not be cut along their width to fit a smaller
area and overlapping between adjacent rolls shall be adopted, this to avoid ravelling after cutting.

- Geotextiles may be cut to length using a sharp blade, scissors or shears. Materials which may ravel shall be heat-treated or
bonded with approved adhesive tape at the cut position. Cutting to size of polymeric sheet geogrids shall be performed before
placing.
- Care shall be taken to ensure that reinforcing elements are not damaged or displaced beyond specified tolerances during filling
and compacting. Filling shall be arranged so that no machines or vehicles run over the reinforcing elements. All vehicles and
construction equipment greater than 1 500 kg mass shall be kept more than 2,0 m away from the facing. Suitable compaction
equipment of mass less than1 500 kg may be used within 2,0 m of the facing.
A12.6.7.2 GABIONS
a) Classification of materials
All excavations for gabions shall be excavated in the position indicated on the drawings and to the required dimensions. Overbreak in width or
depth shall be reinstated to the original condition as approved by the Engineer at the Contractor’s cost.
All excavations under this Section shall be classified as specified under Clause A11.1.7.1 of Chapter 11.
b) Constructing gabion boxes and mattresses
(i) General
Gabion boxes and mattresses shall be manufactured from wire mesh of the size and type and selvedge as specified below.
Boxes are generally used for the construction of gabion walls: The boxes are subdivided into cells by diaphragms spaced at 1,0 m
intervals. No diaphragms are required for boxes where the length does not exceed 1,5 m.
Mattresses are generally used as single-layer aprons in revetments, channel linings, etc, which the maximum width of units shall be
2,0 m, and the maximum depth 0,3 m. Mattresses shall be subdivided by diaphragms into cells with a width of 1000 mm. Mattress
shall be installed with diaphragm spaced at 1,0 m in the direction of the flow, unless otherwise specified by the Engineer.
(ii) Selvedges
The cut edges of all mesh used in the construction of gabions, except the bottom edges of diaphragms and end panels, shall be
selvedged with wire with a diameter as specified in SANS 1580.
Where the selvedge is not woven integrally with the mesh but has to be tied to the cut ends of the mesh, it shall be attached by tying
the cut ends of the mesh to the selvedge, so that a force of more than 8,5kN applied on the selvedge in the same plane as the mesh
of a mesh sample of 1,0 m in length will be required to separate it from the mesh.
(iii) Diaphragms and end-panels
The diaphragms and end-panels shall be selvedged on the top and vertical sides only. The end-panels shall be attached by the cut
ends of the mesh wires at the bottom of the panel being twisted around the selvedge on the base of the gabion. Similarly, the
diaphragms shall be attached by the cut ends of the mesh being twisted to the twisted joints of the mesh in the base of the gabion. In
each case the force required to separate the panels from the base shall not be less than 6kN/m.
(iv) Binding and connecting wire
Sufficient binding and connecting wire for all the tying to be done during construction of the gabions as specified in Clause A11.2.7.3
of Chapter 11 shall be supplied with the gabion boxes. The binding wire shall have the same properties as the gabion or mattress
mesh wire.
c) Constructing gabions
(i) Preparing the foundation and surface
The foundation surface on which the gabion boxes are to be installed prior to their being filled with rock shall be levelled to the line
and level shown on the drawings or as directed by the Engineer so as to present an even surface. If necessary, cavities between rock
protrusions shall be filled with appropriately sized material (See Clause A12.6.5.2). Where required, a foundation trench along the toe
of the revetment or wall shall be excavated to the dimensions specified and/or shown on the drawings.
(ii) Geotextile
One layer of geotextile shall be placed where indicated on the drawings or as specified. The geotextile shall be placed, in strips with
a minimum overlap of 300 mm at the joints and shall be properly fastened to prevent any movement or slipping while the gabions are
being placed.
(iii) Assembly
The methods of constructing, stretching, placing in position, wiring and filling the gabions with rock shall generally be in accordance
with the manufacturer's instructions subject to the approval of the Engineer, but nevertheless sufficient connecting wires shall be
tensioned between the vertical sides of all the outer visible cells and a sturdy frame shall be used to prevent the deformation of boxes
as they are being filled with stone. Joints between boxes shall be wired together along all 4 joining edges.
It is essential that the corners of gabion boxes be securely wired together to provide a uniform surface and ensure that the structure
does not resemble a series of blocks or panels. The layout and the tolerances for the layout of the boxes shall be as shown on the
drawings or as specified in the Contract Documentation.
(iv) Rock filling
1. Boxes in gabions
Particular care shall be taken in packing the visible faces of gabion boxes, where only selected stone of the specified size shall
be used so as to obtain an even-faced finish. The boxes shall be filled in layers to prevent deformation and bulging. Boxes shall
be wire braced and filled to just below the level of the internal wire braces, after which the braces shall be twisted to provide
tension. Care must be taken to ensure that consecutive layers of boxes are filled evenly to a level surface ready to receive the
next course.
Filling of gabion boxes by dumping rock shall not be permitted and packing shall be done by means of hand labour.

2. Mattresses used in revetments and aprons
The 0,17 m, 0,23 m and 0,3 m mattresses forming aprons and revetments shall be filled by random stones being packed in the
first layer and by selected stones being used for the top layer so as to resemble normal stone pitching.
A12.6.8 WORKMANSHIP
A12.6.8.1 MSE Walls
a) Facing foundations
Facing foundations shall at all times be level or stepped in facing panel size benches to ensure subsequent panels are always placed level even
if on sloping surfaces. In cases where the Contract Documentation prescribes ground improvement or drainage works to be carried out prior to
commencement of MSE’s, such work shall be undertaken as specified in other sections of Chapter 12, as may be specified.
b) Concrete facings
Concrete quality shall be tested to ensure compliance with 28 day strength, W standards as regards oxygen permeability, water sorptivity and
chloride conductivity as detailed in Clause A20.1.7.5c)(ii) of Chapter 20 and/or as specified in Contract Documentation.
c) Concrete blocks
1. Tolerances
Blocks shall comply with category D2 of BS EN 771-3 and Appendix A1. The width of a block is the distance from the front face
to the soil face and shall be as defined in BS EN 771-3:2003+A1. In some instances the exposed face is often a textured face or
else is a rough face created by splitting a double-width block which may be outside the specified width. The location of any nibs or
voids is critical and the method statement shall provide details of the specific blocks used and the associated operation-sequence.
2. Shear strength
The shear strength between blocks and connection strength between block and reinforcing element shall be determined. Concrete
block facings used in MSE walls shall be manufactured and tested according to SANS 508.
The test methods in ASTM D6916 and ASTM D6638 for measuring block-to-block shear strength and block-to-soil reinforcement
connection strength for blocks with plane-faced bedding surfaces shall be used where required by Engineer.
A12.6.8.2 Gabions
a) General
order to ensure that the quality of materials produced meets the specified requirements. Similarly, the Contractor shall conduct sufficient checks
and controls during construction of the elements to ensure that the required lines, levels and finishes are achieved.
repaired.
b) Tolerances
Tolerances for gabion and mattress materials and dimensions shall conform to the requirements of EN 10223-3.
Both the vertical and horizontal tolerances for gabions facing and mattresses surfaces shall not deviate more than 20 mm over 1,0 m as well as
not more than 50 mm over 3,0 m sections.

B12.6 MECHANICALLY STABILISED EARTH WALLS AND GABIONS
CONTENTS
B12.6.1 SCOPE
B12.6.2 DEFINITIONS
B12.6.3 GENERAL
B12.6.5 MATERIALS

B12.6.8 WORKMANSHIP
B12.6.1 SCOPE
For MSE the provisions of Part A shall apply.
The construction of segmental block walls shall be deemed to be a labour enhanced construction process and this Section therefore includes
work with a large component of labour. This work is included in Part A of this specification. This Part therefore only covers additional specifications
for work to enhance the labour component of construction activities where specified.
The construction of gabions shall be deemed to be a labour enhanced construction process and this Section therefore includes work with a large
component of labour. This work is included in Part A of this specification. This Part therefore only covers additional specifications for work to
enhance the labour component of construction activities where specified.
B12.6.2 DEFINITIONS
B12.6.3 GENERAL

B12.6.5 MATERIALS



Materials
Description
Classification
Material which can be excavated efficiently by means of a suitable shovel with or without the use of a pick
Soft
or other hand-swung tool.
Intermediate

Materials
Classification
B12.6.8 WORKMANSHIP

C12.6 MECHANICALLY STABILISED FILL AND GABIONS
(i) Preamble
pay items.
Table C12.6-1: Items from other Chapters or Sections
C1.7 of Chapter 1 – All applicable
items

C12.6.1 Establishment on site for MSE
C12.6.1.1 For reinforced concrete facing lump sum
C12.6.1.2 For concrete block wall facing lump sum
C12.6.1.3 For metallic facing lump sum
The unit of measurement shall be a lump sum. The tendered lump sum for MSE shall include full compensation for establishing all necessary
plant and equipment on site to carry out the works and for the removal from site of all such plant and equipment including all temporary works
such as access roads, staging, platforms and such like on completion of the works.
Work shall be paid as a lump sum, 50 % of which shall be due when all the equipment is on site, trials (if any) are completed and 25 % of the
first production wall is installed to full height as specified. The second instalment of 25 % shall be payable after 50 % of the walls are installed
and final 25 % instalment after the specified walls are installed, accepted and in service and all equipment is removed from site.
The tendered lump sum shall include full compensation for all post-construction requirements as specified. No extra payment shall be made for
the establishment of additional plant should the established plant not be capable of achieving desired objectives.
C12.6.2 Excavation for wall base foundation cubic metre (m3)
The unit of measurement shall be the cubic metre of material excavated.
The tendered rate shall include for all labour, plant and equipment required for the operation.
C12.6.3 Concrete for wall base foundation cubic metre (m3)
The unit of measurement shall be the cubic metre of required strength concrete.
The tendered rate shall include full compensation for all labour, plant and equipment required for the operation as well as shuttering if necessary.
C12.6.4 Reinforcing steel in wall base foundation
C12.6.4.1 Mild steel ton (t)
C12.6.4.2 High tensile steel ton (t)
The unit of measurement shall be the ton (t) of steel required for the operation.
The tendered rate shall include for all fixing wire, cover blocks and all other labour, plant and equipment required for the operation.
C12.6.5 Preparation of surface for laying metallic strips or geosynthetic square metre (m2)
The unit of measurement shall be the square metre of base surface prepared for the initial (first layer) strips or geosynthetic only. Subsequent
layer preparation costs are deemed to be included in the unit cost for backfill.
The tendered rate shall include full compensation for all materials, labour, plant and equipment required for the operation.
C12.6.6 Metallic reinforcing strips (section dimension indicated) metre (m)
The unit of measurement shall be the metre of metallic strips of required section installed.
The tendered rate shall include full compensation for the supplying of all the materials, labour, plant and equipment required for the operation.
C12.6.7 Metallic reinforcing mesh (section dimension indicated) square metre (m2)
The unit of measurement shall be the square metre of metallic mesh of required section installed.

C12.6.8 Polymer/ Geosynthetic reinforcing strips (section dimension indicated) metre (m)
The unit of measurement shall be the metre of geosynthetic strips of required section installed.
C12.6.9 Polymer/ Geosynthetic reinforcing sheet as specified square metre (m2)
The unit of measurement shall be the square metre of geosynthetic reinforcing sheet installed.
C12.6.10 Fixing mechanism to facings
C12.6.10.1 Strips number (No)
C12.6.10.2 Sheets metre (m)
The unit of measurement shall be the number for C12.6.10.1 (strips) and by the metre for C12.6.10 (sheets).
The tendered rate shall include full compensation for the supplying of all the materials, labour, plant and equipment required for the
installation operation.
C12.6.11 Backfill (material type and compaction requirements indicated) cubic metre (m3)
The unit of measurement shall be the cubic metre of the required material grade compacted to the required standard.
C12.6.12 Facings (type, size and thickness indicated)
C12.6.12.1 For reinforced concrete panel facing square metre (m2)
C12.6.12.2 For concrete block wall facing square metre (m2)
C12.6.12.3 For metallic facing square metre (m2)
The unit of measurement shall be the square metre of panel of the indicated size and thickness.
The tendered rate shall include full compensation for the manufacture, supply, labour, plant and equipment required for the installation as
well as for the sealing of the panel to prevent material egress through panel joints.
C12.6.13 Drainage (type and size indicated) number (No)
The unit of measurement shall be the number of drains installed either on excavation face, behind selected backfill or through facing panels.
The tendered rate shall include full compensation for the supplying of all the material, labour, plant and equipment required for the operation.
C12.6.14 Foundation trench excavation:
C12.6.14.2 Extra over sub-item C11.2.1.1 for excavation in hard material, irrespective of depth cubic metre (m3)
C12.6.14.3 Excavating soft material within 1,5 m below the surface level using labour enhancement cubic metre (m3)
construction methods:
C12.6.14.4 Excavating intermediate material within 1,5 m below the surface level using labour cubic metre (m3)
enhancement construction methods:

Excavation shall be done using conventional construction methods and/or labour enhancement construction methods as specified and measured.
The tendered rates shall include full compensation for the excavation of the material to the required dimensions, lines, levels and grades, temporary
timbering, shoring and strutting, including unavoidable overbreak, the trimming of the trenches and compacting the trench inverts, backfilling of
over excavation and compacting the backfill, keeping excavations safe, dealing with any surface or subsurface water and the loading and disposal
of the excess material as directed. The tendered rates shall also include full compensation for any other operations necessary for completing the
work as specified but excluding surface preparation for bedding the gabions.
Loading and hauling, where applicable, including haul of 1,0 km, shall be measured and paid as specified in Section C1.7 of Chapter 1. Where
the excavation of material is specified by means of labour enhancement construction methods, the tendered rates shall include loading and
transport by wheelbarrow if the material is disposed of or utilised within a radius of 50 m, alternatively loading by hand onto transport vehicles for
such disposal or utilisation elsewhere, within a haul distance of 1,0 km.
For payment purposes a distinction shall be made between materials as classified above under Classification of Materials.
C12.6.15 Surface preparation for bedding the gabions square metre (m2)
The unit of measurement for levelling and preparing surfaces for receiving the gabions shall be the square metre to the neat dimensions of
revetments, aprons or wall foundations.
The tendered rate shall include full compensation for excavating, filling any cavities with rock, and levelling the ground surface to be ready for
receiving the gabion boxes tor retaining walls, aprons and revetments.
C12.6.16 Gabions and mattresses:
C12.6.16.1 Galvanized gabion boxes (dimensions of box) cubic metre (m3)
C12.6.16.2 Polymer coated gabion boxes (dimensions of box) cubic metre (m3)
C12.6.16.3 Galvanized gabion mattresses (dimensions of mattress) cubic metre (m3)
C12.6.16.4 Polymer coated gabion mattresses (dimensions of mattress) cubic metre (m3)
The unit of measurement shall be the cubic metre of the rock-filled boxes or mattresses and the quantity shall be calculated from the dimensions
of the gabions indicated on the drawings irrespective of any accepted deformation or bulging of the completed gabions. Gabions boxes and
mattresses shall be measured to the nearest specified size.
The tendered rates shall include full compensation for supplying all the materials, including rock fill, wire-mesh boxes, galvanizing, PVC-coating,
tying and connecting wires, loading, transporting and off-loading, the assembling and filling of the boxes, disposal of waste, and any other work
necessary for constructing the gabions.
Placing of rock by dumping shall not be allowed and the tendered rates shall also include full compensation for placing rock by means of hand
labour.
C12.6.17 Geotextile (type indicated) square metre (m2)

The unit of measurement shall be the square metre of area covered with approved geotextile placed in position.
The tendered rate shall include full compensation for supplying the geotextile, cutting, waste, placing, joining, overlapping, and securing the
material in position.

D12.6 MECHANICALLY STABILISED EARTH WALLS AND GABIONS
CONTENTS
D12.6.1 SCOPE
D12.6.2 GENERAL
D12.6.1 SCOPE
D12.6.1 GENERAL
For gabions wire used for manufacturing gabions and for tying during construction of the gabions shall comply with SANS 675. Gabion boxes shall
comply with SANS 1580.

documentation related to the specifications.
- Materials as per Clause A12.6.5








12.7 TRENCHLESS METHODS
CONTENTS
A12.7.1 SCOPE
A12.7.2 DEFINITIONS
A12.7.3 GENERAL
A12.7.5 MATERIALS
A12.7.8 WORKMANSHIP

A12.7 TRENCHLESS METHODS

A12.7.1 SCOPE
This Section covers various trenchless methods to install various forms of underground conduit under existing infrastructure or obstruction which
may not be cost-effectively installed from surface or by open excavation. Methods covered include, but are not limited to, pipe jacking, micro-
tunnelling, pipe ramming or horizontal directional drilling (HDD) methods.
A12.7.2 DEFINITIONS
Trenchless Methods - are methods of installing various forms of underground conduit without the excavation of trenches over the installed length
of conduit. These methods include Pipe Jacking, Directional Drilling, Pipe Ramming and Micro-Tunnelling.
Pipe Jacking - is a method for installing a conduit/pipe that serves as initial construction lining and support, installed for stability and safety during
construction, and finally as the service pipe. The pipe is forced forward, or jacked, to advance the conduit.
Micro-tunnelling - is a method of installing a conduit by jacking a pipe behind a micro-tunnel boring machine, generally precluding man entry.
Pipe Ramming - is a method by which a cylindrical tool uses air pressure to pound its way through the ground underneath an obstruction,
simultaneously installing a conduit.
Horizontal directional drilling (HDD) - is a steerable drilling method of installing a small diameter underground services conduit.
Micro-tunnel Boring Machine - is a mechanized excavating machine that is remotely-controlled, steerable, guided and articulated, connected to
and shoved forward by the pipe being installed, usually precluding man entry.
Zone of Active Excavation - the zone of active excavation is the area located within a radial distance about a surface point immediately above
the face of excavation equal to depth to bottom of excavation.
Critical Structure - is an existing service, any building, structure, bridge, pier, or similar construction partially or entirely located within a zone of
active excavation.
Inlet and outlet structures - may be entry and exit points for some applications to especially designed jacking pits in others. Names used in this
text include, entrance/entry and exit, jacking and receiving. These may be circular or rectangular shafts.
A12.7.3 GENERAL
A12.7.3.1 Services and obstructions
A geotechnical investigation shall have been carried out to select the route least affected by known services and which is free of apparent
obstructions. Details of known services and other objects which may constitute an obstruction on site shall be detailed in the Contract
Documentation. Notwithstanding this, unidentified obstructions/services may be encountered.

Before any work can commence the Contractor shall verify the actual position of each known service and bring to the attention of the Engineer
any service that is not recorded in the Contract Documentation.
Should an unidentified obstruction be encountered which prohibits further advance of equipment, the Engineer and Contractor shall jointly devise
a method for penetration/avoidance/possible relocation. The cost of additional operations required for this task shall be agreed between Engineer
and Contactor prior to commencement.
The provisions of Clause A2.1.3.2 of Chapter 2 regarding the protection of services shall be applicable.


(as per Part D) related to the specifications, test results as required together with samples of materials and where applicable, materials designs
that he proposes to use in the construction of the works to the Engineer for his acceptance/approval as provided for in the Contract Documentation.
of the works:
A12.7.7.1 Compatible materials for pipe jacking 4 weeks before construction
Materials Approvals
Details and product certificates for materials for
A12.7.5.1 Pipe jacking, Horizontal directional drilling, Pipe 2 weeks before ordering or delivery
ramming or Micro-Tunnelling
A12.7.7 Construction Method Statements

A12.7.7.2 b) Execution of Pipe jacking works 4 weeks before construction
A12.7.7.3 b) Execution of Horizontal directional drilling
A12.7.7.4 a) Execution of Pipe ramming
A12.7.7.5 a) Execution of Micro-tunnelling 4 weeks before construction
A12.7.3.4 Removal of surplus material/ spoil

Removal of excess material/ spoil is the Contractor’s responsibility as is well as restoration of the site to conditions which existed prior to
construction. The method for removal or final disposal of spoil shall be not be detrimental to and shall be appropriate to the works. The costs of
removal and final disposal shall be included in his rates.
A12.7.3.5 Pipe jacking

Pipe jacking is a method for installing a casing or sleeve that may serve as a direct conduit for liquids or gases, or as a duct for pipe, cable, or
wire line services. It is a multi-stage process consisting of constructing a temporary horizontal jacking platform and a starting alignment track in
an entrance jacking pit at the desired elevation. The sleeve/conduit is then jacked from a thrust block by manual control along the starting alignment
track while simultaneous excavation of soil/rock is accomplished by excavating the face under a shield.
Spoil is transported back to the entrance pit either manually or using light wagons on rails. Pipe jacking typically provides limited tracking and
steering as well as limited support to the excavation faces.

A12.7.3.6 Horizontal directional drilling
Horizontal directional drilling is a trenchless method for installing a casing/sleeve that serves as a direct conduit for liquids or gases, or as a duct
for pipe, cable, or wire line products. It is a multi-stage process consisting of drilling a pilot bore along a predetermined path and then pulling the
desired casing/sleeve back through the drilled space. The vertical profile of bore alignment is typically in shape of an inverted arc. When necessary,
enlargement of the pilot bore hole to accommodate a casing/sleeve greater than the pilot bore cross section is accomplished by back-reaming.
This is accomplished by the casing/sleeve being simultaneously pulled back through the pilot bore space. Bore steering is accomplished by the
orientation of drill bit head as it is being pushed along an alignment by an above-ground hydraulic jack. Orientation and tracking of drill bit are
determined by an above-ground radio-detection device which picks up a signal generated from a radio transmitter contained within the drilling bit.
This radio signal is translated into depth and alignment. In order to minimise friction and provide a soil stabilising agent, a purpose-selected,
appropriate drilling fluid is introduced to the annular space created during boring operations. Rotation of the bit in soil wetted by drilling fluid creates
a slurry. This slurry acts to stabilise the surrounding soils and prevents collapse of the borehole and loss of lubrication. Drilling fluid quantities
must be designed for the soil and ground water conditions. In order to confine any free-flowing slurry at the ground surface during pull back or
drilling, sump areas shall be created to contain any escaping slurry that might damage or be hazardous in the surrounding areas. All residual
slurry shall be removed from the surface and the site restored to pre-construction conditions.
A12.7.3.7 Pipe ramming

Pipe Ramming uses a tool and compressed air to drive a bit through ground under the desired/existing facility. The tool is cylindrical in shape and
ranges in size from 25 to 200 mm in diameter and between 1,0 and 2,0 m long. It is made from metal. Different manufacturers have different front
styles and control mechanisms. Some have bullet-shaped fronts and others have a stepped front similar to a uni-bit (cone or truncated cone bit).
A12.7.3.8 Micro tunnelling

Micro-tunneling is the construction of conduits by one-pass methods without man entry. These construction methods involve jacking pipe following
hand-shield excavation or a micro-tunnel boring machine, with the pipe serving as both tunnel liner during construction and pipe after completion
of construction.
Micro-tunneling is a remotely controlled, guided pipe installation process that provides continuous support to the excavation faces. Guidance
systems usually consist of a laser mounted in the tunnelling drive shaft which communicates a reference line to a target mounted inside the micro-
tunnel boring machine articulated steering head. The micro-tunneling process provides the ability to control excavation face stability by applying
mechanical or fluid pressure to counterbalance earth and hydrostatic pressures.

A12.7.4.1 General
Where design by the Contractor for any technique to be carried out, is, in terms of the Contract Documentation, the responsibility of the Contractor,
all the aspects given below shall be taken into consideration in carrying out these obligations.

- Material type and quality and properties,
- Limits of the area and depths to which boring shall be conducted,
- Concrete/grout mix design,
- Bentonite slurry mix design,
- Sequence of installation,
- Permissible limits (pressures, flow rates),
- Quantities of grout/other materials (if required) to be injected/used,
- Measurable properties to be achieved over the life span of the project,
- Anti-corrosion requirements,
- Environmental and safety requirements specific to the techniques to be executed,
- A definition of objectives and control criteria,


processing of materials and all other measures to be carried out in meeting the requirements as specified in the Contract Documentation.
- The Contractor shall provide a quality management plan indicating his proposed quality assurance testing programme which shall allow, if
necessary, testing at each treatment position as required. Testing methods to be employed shall be as specified in the Contract Documentation.

A12.7.4.2 Contractor’s design
The Contractor shall submit the following in his detailed method statement for the specified works
a) Works methodology
A brief description of proposed methodology shall be given. The description should be sufficient to convey the following:
- The proposed method of construction and type of face support where relevant,
- Manufacturer of and type of equipment proposed,
- The type of lighting and ventilation systems where man entry is desired
- The number and duration of shifts planned to be worked each day,
- The sequence of operations,
- The locations of access shafts and work sites,
- The method of spoil transportation from face, surface storage and disposal location,
- The capacity of jacking equipment and type of cushioning,
- Identify critical structures and utility crossings and special precautions proposed.
b) Drawings and calculations

The Contractor shall, for record purposes, submit drawings, and calculations for any support system designed by him. The drawings shall be
adequate for construction and include installation and joint details. Documents must be signed by a Professional Engineer.
Calculations shall include clear statements of criteria used for design as described below:
- The Contractor is responsible for the selection of appropriate pipe and pipe joints to withstand jacking forces, pulling or other forces and any or
other construction loads in combination with overburden, earth and hydrostatic loads. Design of any pipe indicated on the drawings considers
in-place loads only and does not take into account any construction loads. Criteria for the longitudinal loading (jacking forces) on pipe and joints
shall be determined by the Contractor, based on the selected method of construction.
- Jacked pipe shall be designed to withstand the thrust or pulling forces of Pipe jacking, Pipe ramming, Micro-Tunnelling, shield or pipe advance,
without damage or distortion. Propulsion jacks shall be configured so that the thrust is uniformly distributed and will not damage or distort the
pipe.
- Loads from handling and storing shall be taken into account.
- The criteria contained in TMH 7 parts 1 and 2 are to be used.
- The Contractor shall provide pipes of diameter shown on the drawings. Substitution of the pipe/s with larger diameters to suit Pipe Ramming,
Pipe jacking, Horizontal Directional Drilling or Micro-tunnel boring machine equipment availability will only be permitted if the Contractor
demonstrates that design flows and velocities can be achieved.
A12.7.5 MATERIALS
A12.7.5.1 General
and shall be subject to the approval of the Engineer. The Contractor shall submit details and product certificates where appropriate to the Engineer
two weeks before ordering and delivery to site.

a) Drilling Fluids
A mixture of bentonite clay or other approved slurry and potable water shall be used as a cutting and soil stabilisation fluid. Viscosity shall be
varied to best fit the soil conditions encountered. Water shall be clean and fresh, with a pH greater than 6.
No other chemicals or polymer surfactants are to be used in drilling-fluids without the written consent of the Engineer and after a determination is
made that the chemicals to be added are not harmful or corrosive to the facility and are environmentally safe.
b) Pipes
Materials must meet or exceed following standards:
Table A12.7.5-1: Material Standards for DD Installation
Material Type Pressure
SANS/ISO 4437
Polyethylene (PE) ASTM D 2447
ASTM 2513,
SANS 4427
STM D 2447
High Density Polyethylene (HDPE) ASTM D 3350
ASTM F714
ASTM 2513
SANS /ISO 966-1
Polyvinyl-Chloride (PVC)
SANS /ISO 966-2
SANS/ISO 16422
Un-plasticised Polyvinyl-Chloride (U-PVC)
AWWA C200API 2B
Steel
ASTM A139 Grade BAPI 2B (Non-pressure)

a) Materials approved for installation within the road reserve shall be selected based on their suitability for the construction methods as defined
in Table A12.7.5-2 below.

Table A12.7.5-2: Casing/sleeve suitability by construction method
Type Pipe/Casing installation Mode Suitable Pipe/Casing Material
Steel
Pipe Jacking (PJ) Jacking
Reinforced concrete pipes (SC type, D100)
Ductile iron pipes, fibreglass reinforced polymer

mortar pipes, polymer concrete pipes , pre-
Micro-tunnelling (MT) Jacking stressed concrete cylinder pipes, reinforced
concrete cylinder pipes, reinforced concrete
pipes, steel pipes , PVC pipes
b) Materials standards for pipes are given in in Table A12.7.5-3 below.

Table A12.7.5-3: Material standards for Pipe Ramming and Micro Tunnelling installations
Material Type Non-Pressure Pressure
AWWA C150/C151 SANS 1835: 2017

Ductile Iron (DI)
ASTM A716, A747 AWWA C150/C151
Fibreglass Reinforced Polymer Mortar (FRPM) ASTM D 3262 ASTM D3517AWWA C950
Polymer Concrete (PC) DIN 54815-1 & 2 N/A
Pre-stressed Concrete Cylinder Pipe (PCCP) N/A AWWA C300
Reinforced Concrete Cylinder Pipe (RCCP) N/A ASTM C361
ASTM C 79 SANS 676, SANS 677

Reinforced Concrete Pipe (RCP)
ASCE 27-00 ASTM C 361AWWA C300/C302
ASTM A139 Grade B(1)
Steel AWWA C200API 2B(2)
API 2B(2)
Vitrified Clay Pipe (VCP) ASTM C1208EN 295-7 N/A
Note (1) No hydrostatic test required (2) Dimensional tolerances only
A12.7.5.4 Pipe ramming and Micro-tunnelling

a) Steel pipe casing
The Institute of Welding which is an Authorized National Body (ANB) of the International Institute of Welding (IWW) require that the steel casing
diameter shall be more than 150 mm larger than the largest outside diameter of the carrier pipe. Casing pipe shall be straight seam or seamless
pipe. All steel pipe may be bare inside and out, with the manufacturers' recommended minimum nominal wall thicknesses to meet the installation
and loading requirements. Coatings to extend service life may be specified. All steel casing pipe shall be square cut and have dead-even lengths
which are compatible with the pipe ramming or pipe jacking equipment.
All steel pipe casings and welds shall meet or exceed the thickness requirements to achieve service life requirements in the Contract
Documentation. Steel pipe casing of insufficient length shall achieve the required length through fully welded joints. Joints shall be air-tight and
continuous over the entire pipe-circumference with a bead greater than that required to meet thickness criteria of the pipe wall. All welding shall
be performed by a welder qualified from the Southern African Institute of Welding which is an Authorised National Body (ANB) of the International
Institute of Welding (IWW).
b) Reinforced concrete pipe casing
In addition to above concrete pipe standards, pipe shall comply with the following minimum requirements:
- 35 MPa concrete compressive strength at 28 days,
- Full circular inner and/or outer reinforcing cage
- Multiple layers of steel reinforcing cages, wire splices, laps and spacers that are permanently secured together by welding in place
- Straight outside pipe wall with no bell modification,
- Elliptical reinforcing steel shall not be used.
- Single cage reinforcement shall have 25 mm minimum cover from the inside wall,
- Double cage reinforcement shall have 25 mm minimum cover from each wall,
- Joints shall be the gasket type,
- Additional joint reinforcement/bracing shall be provided if required.
- Upon installation, the Engineer may, at his discretion, require that the Contractor perform concrete wiping or injection of joints if it is believed
the joints did not maintain water tightness. No additional payment will be made for this operation.

A12.7.6.1 Pipe jacking equipment
The pipe jacking system shall:

- Have main jacks mounted in a jacking frame located in the start jacking pit/shaft,
- Have a jacking frame which successively pushes a string of connected pipes following the excavation equipment towards a receiving
pit/shaft,
- Have enough jacking capacity to push the excavation equipment and a string of pipes through ground and may incorporate intermediate
jacking stations, if required,
- Have a capacity at least 20 % greater than the calculated maximum jacking load,
- Each set of jacks shall be fitted with a suitably calibrated pressure gauge in good working order such the actual jacking forces can be
read at any time during the jacking operation
- Develop a uniform distribution of jacking forces on the pipe-end using spreader rings and packing, measured by operating gauges,
- Provide and maintain a pipe lubrication system at all times to lower the friction developed on the pipe surface during jacking,
- Use jack thrust reactions for pipe jacking that are adequate to support the jacking pressure developed by the main jacking system.
Special care shall be taken when setting the pipe guide rails in the jacking shaft to ensure correctness of alignment, grade, and stability,
- Provide equipment to maintain proper air quality of manned tunnel operations during construction in accordance with OHS
requirements,
- Enclose lighting fixtures in watertight enclosures with suitable guards and provide separate circuits for lighting, and other equipment,
- Have electrical systems that conform to the appropriate codes,
- Use a tunnel shield. If a hand shield is used for pipe-jacking (with or without attached mechanised excavating equipment), this shield
must be capable of handling the various anticipated ground conditions. In addition, the shield shall:
- Conform to the tunnel shape with a uniform perimeter that is free of projections that could produce over-excavation or voids. An
appropriately sized overcutting bead may be provided to facilitate steering,
- Be designed to allow the tunnel face to be closed by use of gates or breasting boards without loss of ground.

a) Installation equipment
The Contractor shall ensure that appropriate equipment is provided to facilitate the installation as follows:
- Equipment shall be matched to the pipe size installed.
- Contractor to ensure drill rod meets required bend radius,
- Multiple pipe or conduit installations shall be less than the total outside pipe diameter.
The equipment shall be in good working order. Should the type of rig and/or equipment prove inappropriate for the requirements or conditions on
site, these shall be replaced by suitable equipment at the Contractor’s cost.
b) Locating and tracking
The Contractor shall provide details of his proposed method of locating and tracking the drill head during pilot boring. Walkover, wire line, and
wire line with surface grid verification as approved by the Engineer, shall be accepted methods of tracking directional bores. Locating and tracking
systems shall be capable of ensuring the intended installation is achieved. If an area of radio signal interference is expected to exceed 2,0 m, the
Contractor shall provide a suitable alternative tracking system. Locating and tracking systems shall provide information on:
- Clock and pitch,
- Depth,
- Transmitter temperature,
- Battery status,
- Position (x and y),
- Azimuth, where direct overhead readings (walkover) are not possible (i.e. subaqueous or limited access) transportation facility,
- Proper calibration of equipment,
- Alignment readings or plot points shall be taken and recorded every 2,0 m.
c) Monitoring/survey
All facilities shall be installed in such a way that their location can be readily determined by electronic designation after installation. For non-
conductive installations this shall be accomplished by attachment of a continuous conductive material either externally, internally, or integrally with
casing/sleeve. Either a copper wire line or a coated conductive tape for this material may be used. Any break in conductor must be connected by
an electrical clamp of brass or solder and coated with a rubber or plastic insulator to maintain the integrity of connection from corrosion.

a) General
The tool, comprising a bit of either bullet, cone or truncated-cone shape, varying from 25 to 200 mm in diameter and 1,0 to 2,0 m length is powered
by oil and compressed air in jack-hammer fashion. As the tool pounds through the ground it compresses the soil and this compaction ensures a
stiffened annulus which prevents collapse, facilitating casing installation.
The Contractor shall make use of specialist Sub-Contractors experienced in the use and maintenance of the above equipment.

A12.7.6.4 Micro-tunnelling boring machine
a) General
Full directional guidance of a shield shall be used. The Contractor shall employ micro-tunnelling equipment capable of handling the various
anticipated ground conditions and is capable of minimising the loss of soil ahead of and around the machine and shall provide satisfactory support
of the excavated face.
Micro-tunnel boring machines shall conform to the tunnel shape with a uniform perimeter that is free of projections that could produce over-
excavation or voids. An appropriately sized overcutting bead may be provided to facilitate steering. In addition it shall be:
- Capable of full-face closure,

- Equipped with appropriate seals to prevent the loss of bentonite lubricant,
- Capable of correcting roll by reverse drive or utilising fins,
- Designed to handle adverse ground conditions including ground water ingress,
- Equipped with a visual display to show the operator the actual position of the micro-tunnel boring machine relative to the design reference.
b) Performance requirements
Micro-tunnel boring machines shall be:
- Capable of providing positive face support regardless of micro-tunnel boring machines type,
- Articulated to enable the controlled sheeting in both vertical and horizontal directions to a tolerance of ± 25 mm from design alignment,
- Controlled remotely from a surface unit,
- Capable of controlling rotation. This is accomplished using a bi-directional drive on cutter head or by using anti-roll fins or grippers,
- Capable of injecting lubricant around the exterior of pipe being jacked,
- Capable of controlling the rise and fall to acceptable tolerances as indicated in the Contract Documentation.
c) Main control system
The main control system of micro-tunnel boring machines shall provide the following information to the operator as a minimum required for
successful operation of micro-tunnel boring machine:
- Deviation of micro-tunnel boring machine from required line and grade of pipeline (normally by reference to a laser beam),
- Grade and roll of micro-tunnel boring machine
- Jacking load,
- Torque and rotation velocity of cutter head,
- Instantaneous jacking rate and total distance jacked,
- Indication of the steering direction.
d) Remote control system
Micro-tunnel boring machines shall have the following features:
- Operation of the system without need for personnel to enter the tunnel. A display available to the operator, at a remote operation console,
showing the shield position in relation to a design reference together with other information such as face pressure, roll, pitch, steering attitude,
valve positions, thrust force, and cutter head torque; the rate of advance and the installed length,
- An integrated system of excavation and removal of spoil and its simultaneous replacement by conduit.
e) Active direction control
Micro-tunnel boring machines shall have the following features:
- Line and grade control by a guidance system that relates actual position of the micro-tunnel boring machine to a design reference, e.g. by a
laser beam transmitted from the jacking shaft along pipe to a shield-mounted target,
- Active steering information which shall be monitored and transmitted to operating console,
f) Jacking system
The jacking system shall have the capability of pushing the micro-tunnel boring machine and pipe through the ground in a controlled manner
compatible with the anticipated jacking loads and pipe capacity.
g) Spoil transportation systems
Where any of the above techniques use a spoil-transportation system, this shall balance soil and ground water pressures using a slurry or earth
pressure balance system, capable of adjustments required to maintain the face stability for the particular soil condition and shall monitor and
continuously balance the soil and ground water pressure to prevent loss of slurry or uncontrolled soil and ground water inflow.
In the case of a slurry-spoil transportation system it shall:
- Provide pressure at the excavation face using slurry pumps, pressure control valves, and a flow meter.
- Include a slurry bypass unit to allow the direction of flow to be changed and isolated, as necessary.
- Include a separation process. The design shall provide adequate separation of the spoil from the slurry so that slurry with sediment content
within limits required for successful micro-tunnelling can be returned to the cutting face for reuse.
- Appropriately contain spoil on site prior to disposal.
- Use a type of separation process suited to the size of tunnel being constructed, the soil type being excavated, and the workspace available
at each work area for the operating plant.
- Allow composition of slurry to be monitored to maintain slurry density and viscosity limits required.
Where a cased auger earth pressure balance system is used:
- It shall be capable of adjustments required to maintain the face stability for the particular soil conditions encountered.
- It shall monitor and continuously balance the soil and ground water pressure to prevent loss of soil or uncontrolled ground water inflow. Using
this system, pressure at the excavation face is managed by controlling the volume of spoil removed with respect to the advance rate.
- Speed of rotation of the auger flight, and the addition of water shall be monitored.

A generator which is suitably insulated for noise ("hospital" type) shall be used in residential or commercial areas.

a) General
Operations shall be conducted in accordance with applicable safety rules and regulations, OHS standards and the Contractor's safety plan.
Methods which include due regard for safety of work-persons, adjacent structures, utilities, and public shall be used. Clean, safe and neat working
conditions shall be maintained.
The Contractor shall identify suitable sources of fresh water for mixing drilling mud. Approvals and permits are required. Methods for operations
shall be used that will minimize ground settlement. The method shall control flow of water and prevent loss of soil into tunnel and provide stability
of face under anticipated conditions.
Power distribution systems shall be identified under the contract or permit provisions. Noise constraints shall be identified.
The Contractor shall establish and maintain construction control points, reference lines and grades for locating bore tip and detect movement of
ground surface and adjacent structures, in any of the Pipe jacking, Horizontal directional drilling, Pipe ramming or Micro-Tunnelling operations.
The control points shall be sufficiently far from work so as not to be affected by activities on site.
If settlement of ground surface occurs during boring which disturbs temporary benchmarks, the Contractor shall re-establish these.
Installation of instrumentation shall not preclude the Engineer, through an independent Contractor or consultant, from installing instrumentation
in, on, near, or adjacent to construction work. Access shall be provided to works for such independent installations.
Spoil shall be removed so as not to create a hindrance to other activities in the area.
Entry, recovery pits, slurry sump pits, or any other excavation which contain drilling fluids shall be restored and cleaned of all excess slurry left
on/in the ground after installation of casing/sleeve. Removal and final disposal of excess slurry or spoils as casing/sleeve is introduced shall be
the Contractor’s responsibility. The cost of restoring damaged pavement, kerbs, sidewalks, driveways, lawns, storm drains, landscape, and other
facilities shall be borne by the Contractor.

a) General
Construction Installation shall be carried out in accordance with SANS 2001-DP8.
b) Locating and tracking
For all installations, the Contractor shall include in detailed method statements his proposed strategy for providing:
- A true indication of where the leading edge of the casing is located with respect to line and grade. This may be provided by a water gauge
(manometer), electronic transmitting and receiving devices, or other approved methods. The Contractor shall indicate the proposed intervals
for checking line and grade, and record keeping on site.
- Equipment of adequate size and capability to install the project. This includes the equipment manufacturer's information for all power
equipment used in the installation,
- Means for controlling over-cut to a minimum, with maximum limited to a 20 mm space around casing pipe circumference,
- Adequate casing lubrication with a bentonite slurry or other approved lubricant and other/or other support measures to ensure no loss of
grout,
- An adequate band around the leading edge of casing to provide extra strength, which reduces skin friction as well as providing a method for
the slurry lubricant to coat the outside of casing,
c) Process
The following shall be complied with in pipe jacking operations:
- The excavation shall be kept within reserves indicated on the drawings and to the lines and grades designated on the drawings and/or given
in the Contract Documentation,
- Operations shall be performed in a manner that will minimize the movement of ground in front of and surrounding the jack,
- Damage to structures and utilities above and in vicinity of operations shall be prevented,
- Open-faced excavations shall be kept breasted or otherwise supported to prevent falls, excessive raveling, or erosion. Standby face supports
shall be provided for immediate use when required. During shut-down periods, the excavation-face shall be supported by positive means
and no support shall rely solely on hydraulic pressure unless continuously attended by a responsible person.
- The excavated diameter shall be to a minimum size to permit pipe installation by jacking with allowance for bentonite injection into the annular
space,
- Whenever there is a condition encountered which could lead to face collapse and/or destabilisation of adjacent structures, operations shall
continue uninterrupted 24 hours per day until this condition no longer exists,
- The Contractor shall be responsible for damage due to settlement from any construction-induced activities.
- Pipe joints shall be cushioned as necessary to transmit the jacking forces without damage to the pipe or pipe joints,
- An envelope of bentonite slurry shall be maintained around the pipe exterior during jacking and excavation operations to reduce exterior
friction and possibility of the pipe seizing in place,
- If the pipe seizes in place and Contractor elects to construct a recovery access shaft, approval shall be obtained from appropriate local
authorities to coordinate traffic control measures as may be applicable and utility adjustments as necessary prior to commencing the work,
- If a pipe section is damaged during jacking operations, or joint failure occurs, as evidenced by inspection, visible ground water inflow or other
observations, the Contractor shall submit his methods for the repair or replacement for approval by the Engineer.
- All facilities shall be such that their location can be readily determined by electronic detection. Non-conductive conduits shall be fitted with a
continuous metallic strip.

a) General
Installations shall be carried out as per ASTM 1962 as directed by the Engineer.
b) Process
For all installations, the Contractor shall include in his detailed method statements his proposed strategy. Monitoring of pumping rate, pressures,
viscosity, and density of drilling fluids shall be carried out during pilot bore, back-reaming, and pipe installation stages, to ensure adequate removal
of the soil cuttings and the stability of borehole. Holes may be used as necessary for excess-pressure relief. To minimise heave during pullback,
the pullback rate shall be determined in order to maximise the removal of soil cuttings without building excess down-hole pressure. Excess drilling
fluids shall be contained at the entry and exit points until they are recycled or removed from site. Entry and exit pits shall be of sufficient size to
contain the expected return of drilling fluids and soil cuttings.
The Contractor shall ensure that all drilling fluids are disposed of or recycled in a manner acceptable to the appropriate regulatory agencies. When
drilling in suspected contaminated ground, the drilling fluid shall be tested for contamination and disposed of appropriately. Any excess material
shall be removed upon completion of bore.
If during installation an obstruction is encountered which prevents installation of pipe in accordance with this specification, this pipe may be taken
out of service and left in place at discretion of the Engineer and shall immediately be filled with an approved cementitious grout. A new installation
procedure and revised plans must be submitted and approved by the Engineer before work resumes.
Restoration for damage remains the responsibility of the Contractor. Any pavement heaving or settlement damage shall be repaired to the
Engineer’s satisfaction.
The diameters given in Table A12.7.7-1 shall be applicable:
Table A12.7.7-1: Maximum Back-Ream Hole Diameter
Pilot Hole Diameter (mm) Back-Ream Hole Diameter (mm)
50 100
75 150
100 200
150 250
200 300
250 350
≥300 Maximum Casing/sleeve OD plus 150 mm

a) General
For all installations, the Contractor shall provide detailed method statements indicating his proposed strategy.
b) Process and quality control
After setting up on site, the probe tip shall be inserted and advanced into the ground using percussive pneumatic/hydraulic techniques under control
of the guidance system such that the desired location at any point along the length is obtained. On exit of the ram-boring probe, back-reaming
techniques shall be used to insert the desired casing/tubing into the pre-formed hole.
A12.7.7.4 Micro-tunnelling
a) General
For all installations, the Contractor shall provide detailed method statements indicating his proposed strategy.
b) Specific micro-tunnel boring machine requirements

Continuous pressure shall be provided to the excavation face to balance groundwater and earth pressures. Shafts shall be of sufficient size to
accommodate the equipment and pipe selected, and to allow for safe working practices. Entry and exit seals shall be provided at the shaft walls
to prevent inflow of groundwater, soil, slurry, and lubricants. Thrust blocks shall be designed to distribute the loads in a uniform manner so that
any deflection of the thrust block is uniform and does not impart excessive loads on the shaft itself or cause the jacking frame to become
misaligned.
The jacking forces applied to pipes shall be monitored and not exceed pipe manufacturer's recommendations.
Pipe lubrication systems shall be functional at all times and sufficient to reduce the jacking loads. The systems shall include mixing/ holding tanks
and pumps to convey the lubricant from the holding tank to the application points at the rear of MTBM. Sufficient fluids shall be maintained on site
to circumvent loss of lubrication.
c) Process
The Contractor shall make immediate corrections to alignment before allowable tolerances are exceeded. When the excavation is off line or grade,
alignment corrections shall be made to avoid reverse grades in gravity sewers,
The volume of slurry flow shall be monitored in both supply and return side of the slurry loop and position of the slurry by-pass valve.
The following shall be recorded:
The pipe jacking pressures per drive,
- The location, elevation and brief soil descriptions of soil strata,

- The ground water control operations and piezometric levels,

- Any lost ground or other ground movement or any unusual conditions or events,
- If a drive is halted the Contractor shall indicate reasons for if a drive is halted operational shutdown.
A12.7.7.5 Monitoring and records

The Contractor shall:
• Record elevations to an accuracy of 3,0 mm for each monitoring point location Monitoring points should be established at locations protected
from damage by construction operations, tampering, or other external influences. Elevations shall be recorded to an accuracy of 3,0 mm for
each monitoring point location.
• Record the ground surface elevations on the centerline ahead of operations at a minimum of 20 m intervals or at least three locations per
tunnel drive. For pipes greater than 1,5 m diameter, also record similar data at approximately 5,0 m each side of centerline. Settlement
monitoring points must be clearly marked by studs or paint for ease of locating,
• Monitor ground settlement directly above and 3,0 m before and after utility or pipeline intersection.
- Prior to zone of active excavation reaching that point,
- When tunnel face reaches a monitoring point (in plan), and,
- When the zone of active excavation has been passed and no further movement is detected.
All records shall be gathered and maintained by the Contractor in an electronic format as per layout, frequency and detail required by the Engineer
or as he might require modified from time to time. Where so specified these shall be uploaded to an agreed data base on a daily basis which will
be available to the Engineer at all times.
The Contractor shall provide a monitoring report to the Engineer within 14 days of completion of each bore. Completed As-Built drawings shall be
submitted to the Engineer within 30 calendar days. No payment shall be made until required records are delivered.
A12.7.8 WORKMANSHIP
A12.7.8.1 Pipe jacking, directional drilling, pipe ramming and micro-tunnelling
On completion of any casing or non-casing carrier installation, the Engineer shall order pressure tests and any other testing as may be specified

B12.7 TRENCHLESS METHODS
CONTENTS
B12.7.1 SCOPE
B12.7.2 DEFINITIONS
B12.7.3 GENERAL
B12.7.5 MATERIALS
B12.7.8 WORKMANSHIP
B12.7.1 SCOPE
B12.7.2 DEFINITIONS
B12.7.3 GENERAL

B12.7.5 MATERIALS


B12.7.8 WORKMANSHIP

C12.7 TRENCHLESS METHODS
(i) Preamble
infrastructure or services damaged by the Contractor’s activities and for complying with all the requirements of Clause A2.1.3.4 of Chapter
2.
pay items.
6. No separate payment will be made for the hauling of any materials where the material is moved over a distance of less than, and up to,
1,0 km.
C12.7.1 Establishment on site for: (indicate type of operation: Pipe Jacking, Horizontal directional lump sum
drilling, Pipe Ramming, or Micro-tunnelling)
The unit of measurement shall be a lump sum. The tendered lump sum for above shall include full compensation for establishing all necessary
plant and equipment on site to carry out the works and for removal from site of all such plant and equipment including all temporary works such
as access roads, staging, platforms and such like on completion of the works.
Work shall be paid as a lump sum, 50 % of which shall be due when all the equipment is on site and trials (if any) are successfully completed to
the Engineer’s satisfaction. The second instalment of 25 % shall be payable after half-length is installed and the final 25% instalment after full-
length, in service, acceptable installation, and all equipment is removed from site.
No extra payment shall be made for establishment of additional plant, should established plant not be capable of achieving desired objectives.

C12.7.2 Moving to and setting up equipment at each position for (indicate type of operation) number (No)
The unit of measurement shall be the number of positions to which equipment is moved and set up in position. The quantity measured shall be
number of set ups at positions as well as at trial positions or at positions where Engineer ordered re-setup.
C12.7.3 Installing holes (diameter, lining type indicated) to required length for (indicate type of metre (m)
operation)
The unit of measurement shall be the metre of hole installed to length required.
The tendered rate shall include full compensation for inlet and outlet structures, including dewatering sumps and operation of pumps to keep the
Works dry, supplying, installing and extracting temporary casing, installing permanent casing as well as for excavating and disposing of material
resulting from conduit formation.
C12.7.4 Penetrating unidentified obstructions/services (indicate type of operation, i.e. Pipe

Jacking, Horizontal directional drilling, Pipe Ramming or Micro-tunnelling) for penetration of:
C12.7.4.1 Steel or iron metre (m)
C12.7.4.2 Concrete metre (m)
C12.7.4.3 Rock of UCS > 3 MPa metre (m)
The unit of measurement shall be the metre of obstruction penetrated.

The tendered rate for drilling shall include full compensation for drilling, cutting, blasting as may be necessary, as well as supplying, installing and
extracting temporary, and installing permanent casing as well as for disposing of surplus material resulting from penetrating unidentified
obstructions.

D12.7 TRENCHLESS METHODS
CONTENTS
D12.7.1 SCOPE
D12.7.2 GENERAL
D12.7.1 SCOPE
D12.7.2 GENERAL

- Materials as per Clause A12.7 5








12.8 GROUND DRAINAGE
CONTENTS
A12.8.1 SCOPE
A12.8.2 DEFINITIONS
A12.8.3 GENERAL
A12.8.5 MATERIALS
A12.8.8 WORKMANSHIP

A12.8 GROUND DRAINAGE

A12.8.1 SCOPE
This Section covers various methods of ground drainage including wells, horizontal drains, vertical band-or wick drains and drainage blankets.
Unless provided for in the Contract Documentation dewatering of excavations shall be regarded as temporary works and no payment will be made
in this regard. The Contractor’s attention is also drawn to Clause A1.2.3.19 of Chapter 1 in this regard. Groundwater conditions and/ or construction
requirements may necessitate the design and application of site-specific dewatering system/s. Where such works are included under the Contract
Documentation these shall be carried out as specified under Section A12.12.
A12.8.2 DEFINITIONS
Wells - comprise preformed holes or trenches from which water is extracted by dewatering pumps to lower the water table /phreatic surface
thereby improving stability and/ or enabling excavation.
Horizontal drains - are sub horizontal drainage holes installed to intercept saturated material horizons in soil and rock slopes. Slotted collector
pipes or band drains, generally wrapped in a geosynthetic filter fabric or geotextile filter jacket to retain fine soil and rock particles, are inserted in
the drilled holes to drain collected moisture.
Vertical drains - are vertical drains comprising pre-manufactured long cylindrical formed geosynthetic filter socks that can be sand filled or have
cuspated cores wrapped in a geotextile filter jacket installed in a regular grid into soft compressible soils to provide preferred drainage paths to
accelerate consolidation settlement.
Sand drains - are vertical drains comprising columns (typically 150 mm to 250 mm in diameter) of highly permeable sand in holes formed in the
ground by either drilling or driving in a regular grid. These are used in stiff and dense soils which preclude the effective installation of band drains
Geosynthetic Drains - also referred to as Blanket drains comprises a geotextile filter fabric encapsulated/wrapped layer of drainage material
such as free draining sands or drainage stone constructed to intercept, collect or counteract moisture movements beneath structures such as
embankments and in roadbeds in cuttings.
Geocomposite drains - consist of drainage cores acting as a flow nets which are enclosed in a geotextile.
Construction Dewatering - is the removal or draining of groundwater from a riverbed, construction site or caisson by pumping or other means.
Dewatering may be implemented before subsurface excavation for foundations or shoring to lower the water table. (See Section A12.12)
A12.8.3 GENERAL
Where so indicated by the Engineer the Contractor shall prepare detailed method statements for each facet of ground drainage describing key
aspects such as construction methodology, key plant, materials, personnel as well as any programme constraints of the envisaged construction
process.


of the works:
Method Statements
A12.8.7.1 Wells 2 weeks
A12.8.7.2 Horizontal Drains 2 weeks
A12.8.7.3 Vertical Drains 2 weeks
A12.8.7.4 Geosynthetic/Blanket Drains 2 weeks
Materials Approvals
A12.8.5.1a) Materials for Wells 2 weeks
A12.8.5.2a) Materials for Horizontal Drains 2 weeks
A12.8.5.3a) Materials for Vertical Drains 2 weeks
A12.8.5.4a) Materials for Geosynthetic / Blanket Drains 2 weeks
A12.8.3.3 Wells
Wells provide an effective means of drawing down water tables / phreatic surfaces in permeable to slightly permeable materials such as sandy
soils and gravels resulting in increased stability and excavatability of in situ materials with reduced risk of sidewall collapse.
Wells generally comprise drilled holes fitted with slotted pipes and filter elements from which collected water is withdrawn by pumping. Temporary
wells may be dewatered employing surface pumps while permanent systems shall have submersible pumps installed as instructed by the Engineer
Well systems may employ suction or positive displacement. For suction systems the maximum effective depth is about 6,0 m, for suction type
systems. Positive displacement systems do not have any limit as single and multiple stage pumps may be used
Installations may comprise individual single installations or multiple well points, sometimes linked to a base station/monitoring point.
The purpose of the wells shall be indicated in the Contract Documentation. Wells may be required for a fixed period such as during construction
or may be long term where ongoing phreatic level control is required for stability reasons (e.g. springs upstream of structures). Long term
installations will require a permanent source of electrical power to drive the pumps. Connection to the nearest local electricity network will be
required. Where so specified the Contractor shall obtain the necessary approvals for connection to such and have this work done by a competent
firm, to the local authority’s approval.
A12.8.3.4 Horizontal drains

Horizontal drains provide means of to lower phreatic surfaces pore water pressures in potentially unstable slopes or existing embankments that
may have become unstable due to moisture entry thereby and increasing the shear strength of the soil, improving the stability and reducing the
risk of failure. Horizontal drains are commonly used in failed slope repairs where subsurface water is involved in the mechanics of failure as
interceptor drains above and as relief drains within the failed mass.
The drains generally comprise slotted collector pipes installed in holes drilled into the slope at shallow angle above the horizontal. Geotextle filter
socks are fitted over the pipe to prevent material egress.
An array of pipe inclinations and lengths is commonly required. Drains may be installed in fan array/s placed at specific position and elevations to
ensure interception of critical seepage lines. This reduces the number of drilling set ups and facilitates construction of collector systems to manage
discharged water.

A12.8.3.5 Vertical drains (Band / wick or sand drains)
The construction of new embankments or structures induces additional stresses on in situ soils that may create instability or unacceptable
settlements during the life of the structure. Fine grained soils such as clays and silts are often saturated and settlement will only occur if excess
water is expelled through voids in the soil grains and particles. Such soils exhibit low permeability rendering the reduction of pore water pressure
a slow process.
Vertical band/ wick drains or sand drains provide means of increasing the rate of consolidation, and is aimed at reducing construction time for
earth embankments.
An early constructed surcharged embankment (or preload) provides further means to accelerate settlements and minimise the long-term residual
deflections (See Clause A5.2.7.9 of Chapter 5).
A12.8.3.6 Geosynthetic drains

Geosynthetic drains, also referred to as blanket drains, generally comprise a layer of free draining material encapsulated or wrapped in a
geosynthetic. The construction of geosynthetic drains shall not commence before the Engineers approval of the preparatory work at the base and
tie-ins with existing materials/ construction works. Particular attention shall be paid to the provision of the required grade over the full area of the
drain and discharge means specified in the Contract Documentation.
A12.8.3.7 Construction dewatering

Dewatering for the removal or draining of groundwater from a riverbed, construction site or caisson may be done by gravitational draw off through
excavated channels, by bailing or by pumping from sumps or wells.

A12.8.4.1 General
Where design by the Contractor for any ground drainage technique to be carried out is, in terms of the Contract Documentation, the responsibility
of the Contractor, all the aspects given below shall be taken into consideration in carrying out these obligations.
- Any test data, that may be available,
The following additional aspects, where applicable, shall also be addressed:

processing of materials and all other measures to be carried out in meeting the requirements as specified in the Contract Documentation.
- The Contractor shall provide a quality management plan indicating his proposed quality assurance testing programme which shall allow, if
necessary, testing at each treatment position as required. Testing methods to be employed shall be as specified in the Contract Documentation.
A12.8.4.2 Typically specified items

The following, as may be applicable shall normally be specified by the Engineer and reflected in the Contract Documentation:
- Drilling method, as may be applicable
- Provisional positions of drains
- Lengths of drains
- Spacing of treatment positions
- Quality and workmanship requirements
- Environmental and safety requirements specific to the techniques to be executed
A12.8.4.3 Available information

- Description of the objectives and the control criteria
- Projected optimum interception points for dewatering/ moisture withdrawal
- Limitations including information on subsurface services
A12.8.4.4 Additional requirements

- Finishing off of treatment area to specified lines and levels, whether materials are to be removed and replaced by other materials, processing
of materials and all other measures to be carried out in meeting the requirements as specified in the Contract Documentation.
- The Contractor shall provide a quality management plan indicating his proposed quality assurance testing program.

A12.8.5 MATERIALS
A12.8.5.1 General
The Contractor shall submit samples and technical details of the proposed materials for all types of drains described below to the Engineer, for
acceptance at least 2 weeks before the approved programmed trial/construction activity. The source, manufacturer’s technical date and test results
as may be pertinent shall be clearly stated. Where appropriate a prototype of the specified drain shall be assembled and presented for inspection.
A12.8.5.2 Wells
The anticipated depth of the wells shall be given in the Contract Documentation or shall be as determined on site during drilling operations.
Materials for wells shall be as specified below.
a) Drainage pipes
Unless otherwise specified the pipes shall be U-PVC conforming to SANS 966-1, Class 16, generally with a diameter of 125, 140 or 160 mm, to
match anticipated flow and pump capabilities.
The pipes shall be radially slotted with two rows of slots, at 60 degrees either side of the centreline at 5,0 mm intervals. The slot length measured
along the inner chord shall be 25 mm ± 5,0 mm and the slot width greater than 0,2 mm, less than 0,5 mm wide. Joins shall be sleeved and pop
riveted with non-corrodible rivets in addition to being glued with approved solvent cement. The distal end shall be fitted with an end cap, glued
and riveted in place.
b) Sand
The filter sand used to fill the void between the drilled hole sides and the slotted pipe shall be clean, siliceous sand from an approved source with
less than 5 % smaller than 0,425 mm and less than 5 % greater than 1,18 mm. The sand shall also comply with the requirements of SANS 1083.
c) Base station
A base station linking all well points designated as operational by the Engineer and which are fitted with permanent pumps shall be constructed
as per the Typical Drawing in the Contract Documentation. The Base station shall house the flow meter/s.

a) General
Materials for horizontal drains shall be as specified below. The Contractor shall provide the Engineer with a sample of all the materials for his
approval prior to delivery to site clearly stating the source, manufacturer’s technical data and pertinent test results. The Contractor shall allow for
a two-week approval time.
The length of the horizontal drains to be installed shall be specified in the Contract Documentation.
b) Drainage pipes/borehole liners
Unless otherwise specified U-PVC pipes conforming to SANS 966 Class 16 of the specified internal diameter (50, 63 or 75 mm ID, as specified)
shall be used. The wall thickness shall be equal to or greater than 3,0 mm. The pipes shall be radially slotted with two rows of slots, at 60 degrees
either side of the centreline at 5,0 mm intervals. The slot length measured along the inner chord shall be 25 mm ± 5,0 mm and the slot width
greater than 0,7 but less than 0,8 mm wide. To protect the drains from root growth section of pipe within 2,0 m of the ground surface shall not be
slotted unless otherwise specified in the Contract Documentation. Joins shall be sleeved and pop riveted with non-corrodible rivets in addition to
being glued with approved solvent cement. The distal end shall be fitted with an end cap, glued and riveted in place.
c) Geotextile filter sock
The geotextile filter sock shall unless otherwise specified be manufactured from geosynthetic fibre filter fabric dimensioned to provide a snug fit
over the slotted drainage pipe. The manufacture of the sock shall be sufficiently robust to withstand the rigours of installation in the drilled borehole
without separation or distortion and without breaks or tears. Where the socks are not factory manufactured they shall be machine stitched using
non degradable thread and inserted over the pipe with the joins on the inside.
A12.8.5.4 Vertical band / Wick drains

a) General
Vertical Band/wick drains generally comprise cylindrical formed geotextile filter socks filled with sand or a geotextile wrapped pre-manufactured
flat cuspated plastic core/ bands (typically less than 10 mm thick, 100 mm to about 300 m in width) which are installed in a grid of vertically formed
holes to provide preferred drainage paths. These drains are sometimes referred to as geosynthetic composite drains. The type, size and shapes
are selected to match soil and site conditions. The Contractor shall provide the Engineer with a sample of all the materials for his approval prior
to delivery on site clearly stating the source, manufacturer’s technical data and pertinent test results as. The Contractor shall allow for a two-week
approval time.
The geotextile filter sock shall, unless otherwise specified be manufactured from geosynthetic, dimensioned to fit over a plastic core where
specified.
Drains are generally manufactured in long lengths and supplied in large reels and are cut to size following installation. The prefabricated unit shall
be sufficiently robust to withstand the rigours of installation without separation or distortion and without breaks or tears.
b) Sand
The sand used to fill the geotextile filter sock in sand drains shall be a clean, free draining river sand of siliceous origin, free of deleterious materials
and shall comply with the requirements given in Clause A3.1.5.2 b) of Chapter 3.
A12.8.5.5 Sand drains

Sand drains are sand columns formed in predrilled or preformed (driven) holes. The sand shall be as for Band/Wick drains above.

A12.8.5.6 Geosynthetic / blanket drains
a) General
Blanket drains generally comprise a layer of free draining material such as free draining sands or drainage stone up to 500 mm thick encapsulated
or wrapped in a geosynthetic filter.
The Contractor shall provide the Engineer with a sample of all the materials for his approval prior to delivery on site clearly stating the source,
manufacturer’s technical date and test results as may be pertinent. The Contractor shall allow for a two-week approval time.
b) Geosynthetic
Geosynthetic fabric used for wrapping/ encapsulating the drainage material shall be approved by the Engineer.
c) Drainage materials
Unless otherwise specified the drainage materials shall comply with the requirements given in Clause A3.1.5.2b) of Chapter 3.
d) Geocomposite drains
Geocomposite drains Consist of drainage cores acting as a flow net which is enclosed in a geotextile.

A12.8.6.1 Wells
Equipment for the installation of wells generally includes the following equipment:
a) Drill rig
The drill rig shall be capable of drilling the holes of the required diameter for the wells to the required depths in the indicated materials. The rig
shall further be capable of installing the temporary steel casing required for temporary support as drilling progresses.
all materials.
b) Temporary casing
The temporary casing shall be steel and be of such diameter to provide the required thickness of filter sand between the drainage pipe and the in
situ material.
c) Pumps
Unless otherwise specified the pumps to be installed in the wells shall be of the submersible type and with an approved electronic or mechanical
water level sensor to control pump operation. Pumps shall only be installed on the written instruction of the Engineer.
The pumps shall have with flow meters installed in line located in base stations if so specified as described below to record actual total discharge
of each well point. Pumps shall be electrically powered.
The Engineer shall instruct the Contractor as to the performance details of the pumps required following the pumping tests. The Contractor shall
present his proposal to the Engineer for his approval.
d) Flow meters
Following the completion of the pumping tests the Engineer shall provide the Contractor with the performance/ calibration requirements for the
flow meter/s. The Contractor shall provide the necessary equipment required for the installation of the flow meters and provide for the electrical
supply meeting statutory requirements.

Horizontal drains are installed in predrilled holes. Unless otherwise specified in the Contract Documentation the drilling method used may be
selected by the Contractor to suit the prevailing ground conditions and may comprise percussion, rotary diamond or auger drilling.
The size of the hole shall be appropriate to the specified diameter of the slotted pipe but shall not be less than 75 mm.
A12.8.6.3 Vertical drains (Band /Wick /Sand drains)

Equipment for the installation of vertical drains generally includes
- A hollow steel mandrel, which houses the drain material,
- An excavator fitted with a leader and vibrating device to drive the mandrel into the ground,
- A sacrificial steel anchor plate to hold the installed drain securely in place.
- The installation equipment shall be fitted with a measuring device which indicates at all times the depth of the mandrel
- Suitable drilling rig/s and ancillary equipment to form holes of the required diameter for sand drains (where applicable),
A12.8.6.4 Geosynthetic / Blanket drains

Conventional construction plant and equipment is used for the construction of Geosynthetic/ blanket drains.

A12.8.7.1 Wells
a) General
The Contractor shall submit detailed method statements for the construction of wells to the Engineer for his approval two weeks before the
programmed commencement thereof. These shall describe aspects such as construction methodology, programming and other salient
information.
The provisional positions of the wells shall be indicated on the plans and/or drawings. Access to these positions shall be agreed with the Engineer
on site and the Contractor shall, in executing the works, ensure that damage to the environment is limited. As works proceed the Engineer may
change the positions of the well points and increase or reduce the number of wells to be installed.
The purpose of the well shall be indicated in the Contract Documentation. Wells may be required for a fixed period such as during construction or
may be long term where ongoing phreatic level control is required for stability reasons (e.g. springs upstream of structures). Long term installations
will require a permanent source of electrical power to drive the pumps. Connection to the nearest local electricity network will be required. Where
so specified the Contractor shall obtain the necessary approvals for connection to such and have this work conducted by a competent firm, to the
local authority’s approval. Hole diameters, casing diameters and drainage pipe/ liner diameters shall be approved by the Engineer and shall
provide the required cover of filter sand around the slotted pipe/liner.
b) Trials
Where so specified the Contractor shall install a trial well/s to demonstrate the suitability of the drilling method employed and his ability to install
the slotted drainage pipe/lining and surrounding the sand filter. No production work may continue until the Engineer’s approval of the installed trial
well is obtained. Payment will only be made for successful installations where all the requirements have been met.
c) Process
Following completion of the trial/s the Engineer shall give instructions as to the well depths, hole diameters, drainpipe diameters and other site-
specific parameters, retaining the right to change these should conditions vary across the construction area.
The Contractor shall ensure that his drill rig is set up plumb at the indicated position of the well.
Only bio-degradable drilling aids approved by the Engineer may be used. Bentonite in particular may not be used.
Temporary steel casing shall be inserted as drilling progresses to provide support. The prepared slotted drainage pipe shall be inserted central to
and to the bottom of the hole. The pipe shall extend at least 500mm above the ground surface. Filter sand shall be poured to fill the annulus
between the temporary casing and the drainage pipe. After initial filling, water shall be added through the drainage pipe and sand levels topped
up. Care shall be taken to ensure that the drainage pipe remains in place, central to the casing/hole. When the sand filling has reached the surface
the temporary steel casing shall be carefully extracted ensuring that the drainage pipe remains in place. The filter sand level shall continuously be
topped up during the extraction process.
Where so specified an impermeable plug shall be installed from the specified level to the surface to seal off the drainage pipe from the surrounding
in situ ground. The hole shall then be flushed to remove any debris that may clog the pump sieve or cause blockages. Care shall be taken to
ensure that such flushing does not adversely influence the performance of the well point in any way.
all materials.
After a settling in period of 24 hours, pumping tests, as specified in the Contract Documentation shall be carried out. The results of these tests
shall provide the basis for decisions regarding the further treatment of the well.
The well shall either have a submersible pump installed and be connected to a base station as specified or shall be provided with a lockable
standpipe set in a 500 mm x 500 mm concrete block of 200 mm thickness, protruding 100 mm above the final ground surface and marked as
Where a base station is indicated/ specified it shall be constructed as per the typical drawings provided, sized to meet the requirements determined
on site. The location of any base station/s shall be confirmed by Engineer on site. The provision of power to the base station for the installed
pumps shall be as indicated for in the Contract Documentation.
The Contractor shall submit daily returns indicating activities completed on each working day. The Contractor shall also, for each completed hole/
well provide a record, in a format agreed with the Engineer, indicating/including
- Position of hole/well
- Date/s of drilling
- Depth of well
- Length of temporary casing used
- Length of drainage pipe installed
- Number of bags of filter sand installed
- Detail of top treatment
- Pump test results
- Pump details (where installed)
- Position of pump and associated plumbing installed to connect with base station
- Date completed
- Date tested
- Date of service entry.
- Updated layout plan of area

a) General
The Contractor shall submit detailed method statements for the construction of horizontal drains to the Engineer for his approval two weeks before
the programmed commencement thereof. These shall describe aspects such as construction methodology, programming and other salient
information.
The positions of the horizontal drains shall be indicated on the drawings. Access to the positions shall be agreed with the Engineer on site and
the Contractor shall, in executing the works, ensure that damage to the environment is limited. Where platforms need to be constructed for the
drill rigs the Contractor shall take the necessary steps to ensure their stability as failure may shear installed drains. The design of the outlet/
collector system should not be compromised by these activities.
Holes for horizontal drains shall be inclined 5° (degrees) above the horizontal. The maximum deviation for any hole from the specified slope shall
be 3 % of the actual length drilled with the proviso that the minimum slope at any point in the drain shall be 1 % towards the hole collar to ensure
free drainage. All holes shall be checked for compliance. Any hole not meeting these criteria or which does not reach the specified depth may be
rejected by the Engineer who may order that it be replaced by a correctly installed and aligned hole.
Where so specified, drains shall be installed in clusters that fan outward to provide the specified drain spacings in zones producing water (typically
equal to or less than 8,0 m).
b) Trials
Prior to the installation of working drains the Contractor shall install, under the supervision of the Engineer, trial horizontal drains at locations
indicated by the Engineer to demonstrate that the equipment, methods and materials utilised produce a successful installation in accordance with
the specifications. The number of trials shall be indicated in the Contract Documentation. Payment will be made for successful trial installations.
c) Process
A temporary collector system shall be put in place before drilling is commenced to accommodate anticipated flow to limit erosion and site
degradation.
Only approved drilling fluids that are biodegradable and will not affect the drainage characteristics of the in-situ materials nor block the
geosynthetic filter sock may be used.
The Contractor shall take note that drilling will be through partially to saturated materials and that temporary casing shall be installed. Care shall
be taken so that no flow or loss of in situ materials beyond the diameter of the drilled hole takes place during drilling. The Contractor shall accurately
monitor the volume of the drill cuttings to the satisfaction of the Engineer to confirm that no excess material is removed during the drilling processes.
Should material loss be evident, the works shall be stopped until the situation is remedied. The Engineer’s approval shall be obtained before
commencing with the works.
Representative samples (chips, washings, etc) shall be retained for each metre drilled and stored in appropriately marked plastic bags. No extra
payment will be made therefore and the cost thereof shall be deemed to be included in the drilling rate. Payment will be made for core boxes to
store samples and cores.
The Contractor shall give the Engineer reasonable notice of when he anticipates reaching the required depth in any hole to allow an inspection of
the works before installation of the drain is carried out. Drill rigs may not be dismantled and moved from the hole until inclination surveys have
been done and the Engineer’s written approval for the continuance of the works has been obtained. The Engineer may order the re-establishment
and setting up of any rig moved without his authority, all at the Contractor’s cost.
Should the drilling equipment become lodged in a borehole not allowing further drilling the Contractor shall immediately notify the Engineer thereof
who may rule that a replacement hole be drilled at the Contractor’s cost. The hole shall be flushed on completion to remove any debris that.
Flushing shall continue until the return water is clear.
all materials.
The assembled drain pipe shall be carefully inserted to the full depth of the hole with the slots aligned on the top. The pipe shall not at any stage
be rotated. Once in place the casing shall be removed without any rotation or outward movement of the drain pipe.
On completion of the installation/s the drain outlet shall be constructed as specified in the Contract Documentation.
well provide a record, in a format agreed with the Engineer, indicating/including
- Position of horizontal drain
- Date/s of drilling
- Length and inclination of installed drain,
- Length of temporary casing used
- Length of drainage pipe installed
- Detail of drain outlet (single/multiple unit headwall)
- Date completed
- Updated layout plan showing the position of all installed drains.
A12.8.7.3 Sand drains

The Contractor shall submit detailed method statements for the construction of sand drains to the Engineer for his approval two weeks before the
programmed commencement thereof. These shall describe aspects such as construction methodology, programming and other salient
information.
The procedure for the installation of sands drains shall be as for band/ wick drains but drilling may be required for the formation of the holes and
casing may be required to provide temporary support until the holes have been filled with the specified sand. The casings are withdrawn as the
sand is placed avoiding arching and/or necking. The sand columns are typically 150 mm to 250 mm in diameter.

A12.8.7.4 Vertical band / Wick drains
a) General
The Contractor shall submit detailed method statements for the construction of vertical drains to the Engineer for his approval two weeks before
information. Approval of the Engineer of the installation sequence and methods shall not relieve the Contractor of his responsibility to install the
drains in accordance with the specifications.
Works may only commence once the Engineer has approved all pre- installation works required of the Contractor in terms of the Contract
Documentation.
Prefabricated band/wick drains shall be installed into compressible saturated silts and clays utilising a mandrel by static or vibratory methods to
the specified depths and grid spacing.
The Contractor shall be required to set out the positions of the drains using provided baseline and benchmark/s and shall be responsible for the
protection thereof. All positions shall be numbered /marked as specified. Damaged or lost markers shall be replaced at the Contractor’s cost.
The Contractor shall, unless otherwise indicated in the Contract Documentation, be responsible for penetrating any overlying fill materials to install
the drains. The Contractor may use augering or other approved methods to achieve this but such shall not penetrate more than 500 mm into the
underlying compressible material.
b) Trials
Prior to the installation of working drains the Contractor shall install, under the supervision of the Engineer, trial vertical drains at locations indicated
by the Engineer to demonstrate that the equipment, methods and materials utilised produce a successful installation in accordance with the
specifications. The number of trials shall be indicated in the Contract Documentation. Payment will be made for successful trial installations.
c) Process
Drains shall be installed from the approved working surface to the depths required. The length (or depth to which the drains shall be installed) as
well as the grid pattern required for the drains shall be as specified in the Contract Documentation. Typical spacing may be 1,5 – 2,0 m centres
with depths as great as 50 m.
Equipment for the installation shall be set up within 300 mm of the required position and plumbed prior to installing the drains.
Vertical band/wick drains are installed by a purpose specific rig using a hollow steel mandrel that is advanced through the compressible / soils to
be drained using constant load or constant rate of advancement. The mandrel protects the drain material from damage during advancement or
retraction of the mandrel.
The reel of wick/band drain drainage material is placed on a spool and the band is fed in at the top of the hollow mandrel until it emerges at the
bottom. The wick/drain material is looped through a sacrificial steel anchor which holds the installed drain securely in place.
The mandrel is then vibrated and driven to the required depth whilst the band drain unwinds off the spool and follows.
When the required depth or refusal is reached, the mandrel is removed, leaving the anchored vertical drain securely in place. For sand filed
drains, the drainage sock is filled with the approved free draining river sand before the mandrel is withdrawn.
No raising of the mandrel during the advancement shall be allowed until the required depth is reached. Drains that are damaged or improperly
installed shall be rejected and abandoned in place.
Drains may be terminated if refusal is encountered at a depth less than the specified depth. This shall immediately be brought to the Engineer’s
attention. Refusal shall be defined as installation into non compressible materials underlying the compressible horizon to be consolidated/drained.
Where obstructions are encountered below the working surface during pre-drilling/augering, the Contractor shall complete the drain to the attained
elevation and notify the Engineer before attempting to install further drains. Under the supervision of the Engineer an attempt shall be made to
install the drain within 700 mm of the original position. If the drain cannot be installed to the specified depth, the position shall be abandoned and
the equipment moved to the next position or other action taken as directed by the Engineer. Payment will be made for such works unless the drain
was improperly installed.
On completion of the installed drain the material shall be cut 500 mm above the working surface, where applicable, and be laid flat onto the
working surface and protected from damage by, inter alia, moving equipment until the specified further processes are completed. The Contract
Documentation may require linking of drains to a horizontal drainage system/medium or drainage blanket.
The Contractor shall record the final installation depth of each drain.
The Contractor shall provide the Engineer with a daily report stating which of the scheduled vertical drains were installed that day, their positions
and depths along with any pertinent observations that were made during installation of the drains and post construction performance.
The Contractor shall submit daily returns indicating activities completed on each working day. The Contractor shall also, for each completed
vertical drain provide a record, in a format agreed with the Engineer, indicating/including
- Position of vertical drain
- Date/s of drilling/installation
- Length of installed drain,
- Date completed
- Updated layout plan showing the position of all installed drains.

A12.8.7.5 Geosynthetic /blanket drains
a) General
The Contractor shall submit detailed method statements for the construction of vertical drains to the Engineer for his approval two weeks before
information.
The position/s of the drains shall be indicated on the drawings. Widths thicknesses and drainage materials to be used shall be as specified in the
Contract Documentation. Payment for the construction of the drains blankets shall be made under Chapter 3: Drainage.
A12.8.8 WORKMANSHIP
For horizontal drains the maximum allowable deviation for any hole from the specified slope shall be 3 % of the actual length drilled with the
proviso that the minimum slope at any point in the drain shall be 1 % towards the outer end of the casing to ensure free draining is maintained.
All well points and drainage holes shall be checked for compliance with the specified positioning, hole inclinations and depths and any further
requirements that may be specified in the Contract Documentation. Any hole not meeting the specified is criteria or which does not reach the
specified depth may be rejected by the Engineer who may order that it be replaced by a correctly installed and aligned hole.

B12.8 GROUND DRAINAGE
CONTENTS
B12.8.1 SCOPE
B12.8.2 DEFINITIONS
B12.8.3 GENERAL
B12.8.5 MATERIALS
B12.8.8 WORKMANSHIP
B12.8.1 SCOPE
B12.8.2 DEFINITIONS
B12.8.3 GENERAL

B12.8.5 MATERIALS


B12.8.8 WORKMANSHIP

C12.8 GROUND DRAINAGE
(i) Preamble
2.
pay items.
1,0 km.
C12.8.1 Establishment on site for
C12.8.1.1 Well point construction lump sum
C12.8.1.2 Horizontal drains lump sum
C12.8.1.3 Vertical drains (all types) lump sum
C12.8.1.4 Geosynthetic/Blanket drains lump sum
The tendered lump sum for ground drainage systems shall include full compensation for providing access and establishing all necessary plant
and equipment on site to carry out the works and for the removal from site of all such plant and equipment including all temporary works such as
access roads, staging, platforms and such like on completion of the works.

The work shall be paid as a lump sum, 50 % of which shall be due when all equipment is on site, trials (if any) are completed and the first production
well point is installed as specified. The second instalment of 25 % shall be payable after half the number of well points or drains are installed and
the final 25 % instalment after all well points or drains are installed, accepted, in service and all equipment removed from site.
No extra payment shall be made for establishment of additional plant should the established plant not be capable of achieving desired objectives.
C12.8.2 Provision of access to drain positions (type indicated) lump sum
The unit of measurement shall be the provision of access to the drain positions as specified in the Contract Documentation.
The tendered rate shall include for all labour, plant and equipment required to provide access to the drain positions as specified.
C12.8.3 Moving to, and setting up the equipment for drilling the holes at each well /horizontal/ number (No)
sand drain position (type indicated)
The unit of measurement shall be the number of positions to which the drilling equipment has to be moved and set up in position to drill a drainage
hole. The quantity measured shall be the number of set ups at drain and/or trial drain positions or at positions where the Engineer has ordered
re-drilling of the holes.
C12.8.4 Moving to, and setting up the equipment for installing vertical drains at each drain number (No)
position (size and type of drain indicated)
The unit of measurement shall be the number of positions to which the installation rig, mandrel and other equipment required to install the specified
vertical drains is moved and set to install a vertical drainage hole. The quantity measured shall be the number of set ups at drain positions as
well as at trial drain positions or at positions where the Engineer has ordered re-installation of the drains.
C12.8.5 Drill holes for wells (diameter indicated) to the required depth metre (m)
The unit of measurement shall be the metre of hole drilled to the depth required.
The tendered rate for the drilling of holes for wells shall include full compensation for drilling as well as supplying, installing and extracting temporary
casing as well as for disposing of surplus material resulting from hole formation. Payment will only be made for holes where successful installations
have been accomplished.
C12.8.6 Drill holes for horizontal drains (inclination and diameter indicated) to the required depth metre (m)
The unit of measurement shall be the metre of hole drilled to the depth and inclination required.
The tendered rate for the drilling of holes shall include full compensation for supplying, installing and extracting the driven temporary casing as
well as for disposing of surplus material resulting from the hole having been formed. Payment will only be made for holes where successful
installations have been accomplished.
C12.8.7 Drill holes for vertical sand drains (diameter indicated) to the required depth metre (m)
The unit of measurement shall be the metre of hole drilled to the depth and inclination required.
The tendered rate for the drilling of holes shall include full compensation for supplying, installing and extracting the driven temporary casing as
well as for disposing of surplus material resulting from the hole having been formed.
C12.8.8 Pre- drilling of holes for vertical drains (diameter indicated) to the required depth metre (m)
The unit of measurement shall be the metre of hole drilled to the depth required.
The tendered rate for the pre-drilling of holes for vertical drains shall include full compensation for boring, supplying, installing and extracting the
temporary casing as well as for disposing of surplus material resulting from the hole formation. Payment will only be made for holes where
successful installations have been accomplished.
C12.8.9 Installation of slotted drainage pipes for wells (size indicated) metre (m)
The unit of measurement shall be the metre of slotted drainage pipes for well points installed as specified.

The tendered rate for installing slotted drainage pipes for wells shall include full compensation for the supply and installation of the pipes as
specified (size to be indicated) and for the placing of the filter sand between the pipes and the hole wall as specified including all labour and
overhead costs. Payment will only be made for successful installations where all the requirements have been met.
C12.8.10 Installation of slotted drainage pipes for horizontal drains (size indicated). metre (m)
The unit of measurement shall be the metre of slotted drainage pipes for horizontal drains installed as specified.
The tendered rate for installing slotted drainage pipes for horizontal drains shall include full compensation for the supply and installation of the
pipes as specified complete with synthetic filter fibre geosynthetic sock as specified including all labour and overhead costs. Payment will only be
made for successful installations where all the requirements have been met.
C12.8.11 Installation of vertical drains (type/ size indicated) metre (m)
The unit of measurement shall be the metre of vertical drain installed as specified.
The tendered rate for installing vertical drains shall include full compensation for the supply and installation of the vertical drains as specified
utilising appropriate installation equipment, mandrels, etc including all labour, plant, equipment and overhead costs.
The tendered rate shall also include the costs of centering and filling the synthetic filter fibre geofabric socks with approved free draining sand
during installation where sand filled drains are specified. Payment will only be made for successful installations where all the requirements have
been met.
C12.8.12 Filter sand for wells (type/ size indicated) kilogram (kg)
The unit of measurement shall be the mass of approved filter sand utilised in the construction of the wells.
The tendered rate shall for the filter sand shall include full compensation for the supply of the specified filter sand on site. Payment will only be
made for the theoretical amount of sand utilised in filling the annulus between the drainage pipe and the surrounding soil which shall be taken as
the outside diameter of the temporary casing).
C12.8.13 River sand for vertical drains (source indicated) cubic metre (m3)
The unit of measurement shall be the volume of approved river sand utilised in the construction of the vertical drains.
The tendered rate for river sand shall include full compensation for the supply of the specified river sand on site from identified sources. Payment
shall only be made for the theoretical amount of sand utilised in filling the annulus between the drainage pipe and the surrounding soil which shall
be taken as the outside diameter of the temporary casing.
C12.8.14 Provision and installation of submersible borehole pumps in designated wells provisional sum
Pumping tests on installed wells as well as the number of wells where the yield warrants pump installation will determine the size/capacity of the
submersible borehole pumps to be installed.
C12.8.15 Construction of base station for wells provisional sum
The provisional sum is for the construction of a base station as per the typical drawing, sized to accommodate flow metres for each installed
borehole pump and as a distribution point for the electrical supply to each installed borehole pump. The costs of linking the pumps to the base
station shall also be covered by this provisional sum.

D12.8 GROUND DRAINAGE
CONTENTS
D12.8.1 SCOPE
D12.8.2 GENERAL
D12.8.1 SCOPE
The scope of this section covers the following:
D12.8.2 GENERAL









12.9 SLOPE PROTECTION MEASURES
CONTENTS
A12.9.1 SCOPE
A12.9.2 DEFINITIONS
A12.9.3 GENERAL
A12.9.5 MATERIALS
A12.9.8 WORKMANSHIP

A12.9 SLOPE PROTECTION MEASURES

A12.9.1 SCOPE
This Section covers all aspects of the slope protection work and associated operations for the supply, installation and construction of specialised
measures to mitigate geohazards such as rockfalls, shallow landslides and debris flows. The nature of the geohazards and areas requiring
mitigation shall be as specified and identified by the Engineer on the construction drawings or where instructed by the Engineer in writing during
construction of the works. This often entails the use of special proprietary developed products, techniques, measures and procedures. Include in
these works is the removal of old debris as well as recent debris resulting from rockfalls and/or slips or slides.
Proprietary researched and developed mitigation products are typically proven by way of prototype testing by the manufacturer, and certified by
independent reputable agencies, as being able to perform to the specifications and performance parameters claimed. As a result, and where
appropriate, the Engineer will prepare a design layout(s) of the required installation(s), indicating their location, extent and capacity of the mitigation
measures/products, as well as the associated performance specification required.
Mitigation installations may also be by way of, or by incorporating geotechnical measures and processes specified elsewhere in these
specifications, namely:
- Shotcrete revetments to stabilise and contain loose surficial rock on slopes and cuttings, reinforced either with steel mesh or fibres, typically
anchored back with rock bolts or dowels, may be used to mitigate rockfalls.
- Rock bolts and dowels are used extensively to mitigate rockfalls by anchoring back discrete loose blocks. Rock bolts and dowels are
furthermore typically used in installations of proprietary developed mitigation systems such as rockfall netting revetments, catch fences,
shallow landslide fences and debris flow barriers.
- Gabions, either as walls or revetments and mechanically stabilised earth structures, may be used to mitigate rockfalls and shallow landslides.
Where the foregoing geotechnical methods are specified as elements for the construction of the mitigation installations described hereunder the
specifications, measurement and payments Clauses for the relevant said geotechnical methods as described in Sections A12.2 (Ground Anchors),
A12.5 (Shotcrete), A12.6 (Mechanically Stabilised Earth) and A12.7 (Trenchless Methods) respectively, shall apply. In the event of a conflict
between the requirements of Section A12.9 and the specifications of the relevant aforementioned geotechnical methods referred to above, the
requirements of this Chapter shall take precedence.
A12.9.2 DEFINITIONS
The following definitions, terms, works or expressions shall be defined as assigned hereunder. It is to be noted that these are not exhaustive and
merely represent a selected few used in the field of mitigation measures specified. Accordingly, these do not in any way limit the scope of the
mitigation required or the required outcomes and objectives set out in these specifications.
Rockfall - occurs when a limited discrete number of rock blocks or wedges become detached at height and either free fall, bounce and/or translate
over ground with some speed and momentum.
Active Rockfall Mitigation Measures - are those where the rockfall hazard is either removed by excavation and disposal or stabilised to prevent
falls of ground. These would typically consist of either one or a combination of; barring down of loose rock; anchoring of individual loose blocks
or kinematically unstable wedges of rock; stabilisation of a relatively thin unstable surficial layer of rock by way of anchored rockfall netting or a

shotcrete revetment. The provision of revetments and claddings to slope surfaces such as gabion or precast concrete block walls, either as gravity
structures or anchored back, also constitute active measures against rockfall.
Passive Rockfall Mitigation Measures - are those in which the rockfalls are intercepted, controlled and brought to rest within pre-determined
limits. These would include rockfall barriers such as catch- fences and earth embankments, usually as mechanically stabilised earth
embankments, drape mesh and drop zones and ditches.
Rock Barring or Scaling - shall mean dislodging and removing potentially unstable or loose rock by prizing them off rock surfaces using pinch
bars or other manual means where they are considered by the Engineer to be unstable and a potential hazard. Rock barring is typically undertaken
using rope access or from crane suspended or elevated platforms.
Shallow Landslide - occurs when a relatively small volume of unstable ground slips and translates downhill with some speed.
Debris Flow - is a fluidised mass of mud, soil and blocks of rock, often with ripped up vegetation, which originates when potentially unstable thin
talus slopes or accumulated riverine deposits become super saturated and start flowing. Debris flows can attain high velocities and tend to
become raging torrents of short duration.
Slope Cleaning - shall mean the removal of smaller pieces of loose rock and accumulated debris on rock surfaces and ledges that cannot be
efficiently or effectively removed by barring down. Cleaning is typically achieved by means of high-pressure air-jetting equipment, together with
a high-pressure water jet, if required.
Protective Measures - are the precautions which the Contractor must take to avoid any danger to the public or the workforce or damage to the
road surface, road furniture and infrastructure of the work area at each cutting/slope as a result of the impact of falling barred down rock or any
other reason related to the Contractor’s construction activities.
Design Layout of an Installation - is typically a generic schematic dimensioned representation showing the location and required configuration
of the main components of the said installation(s). These shall include sections through and along the line of each installation as might be required.
Given the allowable tolerances for the relative placement of components, and the strict requirements of the geometrical layout that needs to be
adhered to, the initial design layout as illustrated on the design drawings may need to be adjusted and installations sometimes moved and
rearranged to meet the actual topographical and other constraints of the site.
Wire Rope Anchor - is similar in its functionality to a passive rock dowel, but with the added advantage that the head of the anchor can flex. It is
used extensively in the anchoring requirements of mitigation installations. A wire rope anchor simply consists of given length of wire rope cable
that is folded double and clipped together. The loop formed at the proximal end serves as the anchor head and is provided with a steel thimble
to prevent the rope from kinking and maintaining the required minimum radius when pulled. The wire rope anchor is inserted in a predrilled hole
and installed with only the loop protruding, which serves as the anchor head, where after it is grouted over the full embedded length.
Gap Filling - is typically required along the base of catch fences and shallow landslide fences due to the unevenness/undulation of the ground
surface between adjacent posts. Gap filling requires that infill segments of the rockfall netting of the fences are required to be placed between
the bottom cable and the ground surface to close off the gap. This requires that a separate cable be laid between the posts and pinned and
anchored back to follow the contour of the ground as far as possible.
Weave of Rockfall Netting - is the pattern whereby the steel wire has been plaited to create a continuous uniform netting. These are open
patterns and are woven with variable apertures, measured, described and specified by their geometric shape, area in mm2 and minimum and
maximum dimension in mm.
A12.9.3 GENERAL
A12.9.3.1 Objectives and requirements
Only specialised mitigation products, produced by reputable specialist manufacturers, with a proven and acceptable track record in the field of
design, manufacture and supply of these products, will be eligible for consideration as service providers for slope protection measures. Prototypes
of these products shall have been tested and certified by independent reputable agencies in accordance with the specified standard, as being
able to perform to the specifications and performance parameters claimed.
The installation of rockfall mitigation shall only be undertaken by suitably experienced and equipped specialist geotechnical Contractors with a
proven track record of having successfully undertaken anchoring of slopes and cuttings which shall include slope protection measures.
The works shall be managed and controlled on an on-going daily basis by a works manager with a proven track record. In the event that the
Contractor does not have the necessary experience he shall sub-contract this work to a suitably qualified, experienced and appropriately equipped
sub-Contractor with the required proven track record as specified above. The appointment of a suitable sub-Contractor shall be subject to the
approval of the Engineer.

Where so indicated by the Engineer the Contractor shall prepare detailed method statements for the slope protection measures describing key
aspects such as construction methodology, key plant, materials, personnel as well as any programme constraints of the envisaged construction
process.
It shall be noted that there are construction activities which require the Engineer’s superintendence. Such activity may not proceed or continue
without the Engineer’s superintendence – see Table A12.9.3-1. The Contractor shall furthermore give the Engineer at least 24hrs written prior
notification of such activity.

A12.9.3.3 Materials and materials design

of the works:
Table A12.9.3-1: Approvals/notifications required

Clause(s) Engineer’s approval of: Notice Period
Method statements
4 weeks prior to start of works on any
A12.9.7.1 Method statements for installation of various components
section
2 weeks prior to start of works on any
A12.9.7.1 Amended Method Statement
section
On site facilities for receiving, storing, assembling, inspection
A12.9.7.1 Prior to delivery, Verification on delivery
and verification of specialised materials and anchors
Materials
A12.9.7.1 Inspection, verification and approval of specialised materials 1 week before programmed installation
Process
A12.9.7.1 Traffic accommodation in place, works cordoned off 24hrs prior to inspections, setting out of the
works and/or testing
Proforma on the detail, format and frequency of the records that
A12.9.3.5 2 weeks prior to commencement of works
the Contractor shall submit to the Engineer.
A12.9.7.1
Barring down, making safe of work areas 1 day before initial setting out
Two weeks before programmed
A12.9.7.2 Initial setting out of the works, approval of adjustments
installation date
Inspection of Anchor assemblages, drilling of holes, anchor and Prior to insertion and grouting of anchors,
A12.9.7.2
post excavations, steel reinforcement pouring of concrete
A12.9.3.4 Sequencing the installation of mitigation measures

The Contractor shall scrutinize the approved construction drawings for constructability to ensure that the sequence of installation of mitigation
measures is optimally achieved and meets the requirements of the specification.
The Contractor’s attention is drawn to the possible restriction that the requisite sequence of the installation of the mitigation measures within the
excavation cycle, or elements thereof, may have on the execution of the works, and possibly disruption to normal production. The Contractor shall
allow for the costs and disruption in his rates and programme for undertaking the mitigation installation.
A12.9.3.5 Records
The Contractor and the Engineer shall agree, at least two weeks prior to the commencement of any installation, on the detail, format and frequency
of the records that the Contractor shall submit to the Engineer. Work will not be allowed to commence prior to the requisite agreement on record
keeping being in place. Should the Contractor fail to produce the requisite agreed records timeously or to the required detail, the Engineer may
instruct that all work on the relevant section of the works be suspended until all the outstanding records have been submitted to the required level
and detail.

The Contractor shall design concrete and/or grout that may be required used in carrying out the works as specified. Where applicable, mix
designs shall be complete, be presented on the required forms and shall be presented to the Engineer with samples of all the constituents as
required at least 6 weeks prior to placement
The design for the slope stabilisation measures required to mitigate adverse events is shown on the drawings indicating the position, height,
extent, energy rating and/or capacity and the associated performance specifications required of the various elements. These measures require
installations of mitigation products or, rockfall netting revetments, standard geotechnical measures as indicated and may include processes such
as shotcrete, rock bolts and dowels, gabions and mechanically stabilised embankments. Such may include proprietary researched, designed and
developed mitigation product(s). Notwithstanding the foregoing the Contractor shall in all instances undertake the design of all temporary measures

required to protect the road furniture, infrastructure and components of the work under construction or already complete, from the impacts of falling
rock.
The Contractor shall on the basis of these requirements propose qualifying proprietary researched, designed and developed mitigation product(s),
that will meet the capacities and the performance parameters specified in the Contract Documentation.
Where so required, or where the Contractor submits an alternative design layouts, the standard geotechnical measures and processes contained
in these specifications shall be carried out a suitably qualified and experienced specialist, with proven documented experience in the design and
construction of the required mitigation measures.
Alternative designs shall address indicate
- The location, extent and limits of the mitigation works
- Level of acceptable protection and/or hazard as might apply to the various portions of the protection works.
- Design life and level of corrosion protection required.
- A detailed cost breakdown.
- Testing methods to be employed
- Quality assurance testing program which shall allow for testing at each treatment position/installation.
- Maintenance Requirements.
Alternative designs shall also include the design the barricades to intercept and safely attenuate the kinetic energy and the runout of falling rock
within the designated area(s) and constraints specified. These designs shall be undertaken by a suitably qualified and experienced specialist with
proven documented relevant experience in the design and construction of the required mitigation measures accepted by the Engineer. All designs
given shall be subject to the vetting and approval of the Engineer. All systems shall be assessed for compliance with the guidelines in ETAG 027.
Available information is presented in the Contract Documentation. It is the Contractor’s responsibility to obtain all the other information required
to enable him to meet his obligations in term of the Contract Documentation. The requirements given in Clause A12.9.3 shall be met and.
Notwithstanding the foregoing the Contractor shall in all instances undertake the design of all temporary measures required to protect the road
furniture, infrastructure and components of the work under construction or already complete, from the impacts of falling rock.
A12.9.5 MATERIALS
A12.9.5.1 Finalising the design and ordering of materials
The proprietary designed, developed and tested materials used in the slope protection works may need to be imported and/or are subject to
considerable lead time for manufacture and delivery. The Contractor shall take this into account in the planning and scheduling of the construction
of the works.
The Contractor shall furthermore undertake all the necessary site survey, setting out and measurements required to finalise the design and
dimensioning of the various elements of the installations timeously at the onset of construction so that the requisite orders for the manufacture
and/or delivery can be placed as soon as possible.
A12.9.5.2 Rockfall netting

Rockfall netting may either be installed as a draped mesh, anchored at the crest, free hanging over the slope or cutting, mostly tied off to a lower
support cable at the toe of the slope or cutting, thereby providing passive mitigation, or as a mesh revetment covering the slope or cutting but
anchored and pulled up tight against the rock surface on a regular grid to provide active mitigation.
Rockfall netting is manufactured and shipped to site in rolls of standard length and width. The mesh shall be joined on site during installation to
create a continuous wire mesh revetment. The required spacing/number of clips/shackles shall be as specified by the manufacturer of the
proprietary brand mesh to ensure that joins in the wire mesh panels are at least as strong as the intact mesh itself and do not constitute a potential
line of weakness and preferential failure when loaded to capacity.
In the event of an anchored mesh installation, the clawed face plates attached to the anchors shall be as per the manufacturer’s specifications
and design to ensure safe and optimal load transfer and pull back of the revetment against the rock/ground surface.
The following shall generally be specified in the Contract Documentation and/or drawings
- Static tensile strength of individual wire in MPa used to weave the netting.
- Diameter of the individual wires in mm required for the weave of the netting.
- The construction of the weave of the netting, namely being either, chain link, double twist, ring net, or any other specialised weave as might
be required by the Engineer.
- Minimum and/or maximum dimension and aperture of the weave of the rockfall netting in mm and mm 2, respectively.
- Minimum static tensile strength in kN/m of a mesh panel with minimum width and length of 2,0 m or minimum punching resistance according
to UNI 11437.
- Galvanic coating of wire and wire ropes. Type and Class, namely gm/mm2 or µm thickness.
- Minimum thickness and colour of UV resistant PVC coating, if required.
A12.9.5.3 Catch fences

The specification covers the supply and installation of proprietary designed, developed and prototype tested catch fence system complete with
requisite components and the erection thereof in accordance with the specialist manufacturer’s specifications and the design layout specified in
the drawings and Contract Documentation. All fencing materials shall be ETAG tested and certificates shall be supplied indicating the results of
such testing on that product. Fencing shall be CE certified. The following shall generally be specified and supplied in the Contract Documentation
and/or drawings:
- The Design Layout with fences numbered.
- The ground conditions and geotechnical parameters required for the design of all anchors and post plinths.

- The height of the various fences within the design layout in m.
- The required energy rating in kJ.
- The maximum allowable extension in m of the fence at the working limit.
- Minimum and/or maximum dimension and aperture of the weave of the fence netting in mm and mm 2 respectively.
- Galvanic coating of rockfall netting, wire ropes and posts. Type and Class, namely gm/mm2 or µm.
- Any specific colour or coating in addition to the galvanic coating.
A12.9.5.4 Shallow landslide fences

The specification covers the supply and installation of proprietary designed, developed and prototype tested shallow landslide fence system
complete with requisite components and the erection thereof in accordance with the specialist manufacturer’s specifications and the design layout
specified in the drawings and Contract Documentation.
The following shall generally be specified and supplied in the Contract Documentation and/or drawings:
- The design layout(s).
- The ground conditions and geotechnical parameters required for the design of the anchors and post plinths.
- The height of the various fences within the design layout.
- The weight (mass) of material required to be retained per meter run of fence.
- Minimum and/or maximum dimension and aperture of the weave of the fence netting in mm and mm2 respectively.
- Galvanic coating of fence netting, wire ropes and posts. Type and Class (gm/mm 2).
A12.9.5.5 Debris flow fences

The specification covers the supply and installation of proprietary developed and prototype tested debris flow fence, complete with requisite
components and the erection thereof in accordance with the specialist manufacturer’s specifications and the design layout specified in the drawings
and Contract Documentation.
The following shall generally be specified and supplied in the Contract Documentation and/or drawings:
- The design layout of each fence showing the type, number, location and extent/footprint.
- The ground conditions and geotechnical parameters required for the design of the anchors and the plinths of the posts and lateral and
upslope anchor.
- A description of the nature, composition and total volume in m 3 of the debris to be retained.
- The digital terrain model of the gulley/ravine at and an adequate distance above the site(s) of the debris flow fence(s).
- A description of the conditions and composition of the gulley/ravine to assess its open channel hydraulic conductivity.
- The requisite flows that the fences need to safely intercept.
- Maximum dimension and aperture in mm and mm 2 respectively and type of weave of the fence netting.
- Galvanic coating of rockfall netting, wire ropes and posts. Type and Class, namely gm/mm 2 or µm.

The slope protection installations may require both working from ground level using standard methods and equipment (sometimes modified or
using boom extensions) working at height, using both rope access and light equipment or from platforms suspended from cranes or elevated
platforms, anchored to the slopes.
Drilling shall be undertaken by pneumatic or hydraulically driven drills rigs/drifters fitted with feed motors and percussion rock drills, with adequate
air flushing to remove drill cuttings efficiently. These rigs shall also be fitted with effective dust suppressing and collecting equipment.
The drill rigs and equipment shall be in good working order and capable of producing straight holes to the required depths, dimensions, tolerances,
direction and inclination. The number of rigs and the capacity of the motors shall be such that they can match the production requirements for the
project. Drill bits to be used shall be selected to match the various rock mass conditions to ensure optimal production rates. Drill bits shall
furthermore be sharpened/reground and replaced at prerequisite intervals to ensure optimum penetration rates.
Should the type of rig and/or equipment prove inappropriate for the requirements or conditions on site, these shall be replaced by suitable
equipment at the Contractor’s cost. The drill rig/equipment shall be able to complete all drilling operations, without loss of direction or inclination,
in all materials.
The plant shall be inspected, serviced and calibrated at regular requisite intervals and tested to ensure system functionality, efficiency and
accuracy.
At the commencement of the work the Contractor shall supply the Engineer, for all key plant to be used the requisite maintenance plans and
schedules as required by the manufacturer, to keep them in the requisite working order. The Contractor shall submit monthly returns summarising
all maintenance and repair work undertaken on the key plant for the duration of the contract.
The Contractor will be obliged to adhere to the maintenance schedules submitted, failing which the Engineer may suspend the further use of the
item of plant in question until the requisite maintenance has been undertaken.

A12.9.7.1 General
a) Method statements
Detailed method statements for each section of the slope protection works shall be submitted to the Engineer for his approval at least two weeks
before any slope protection works are carried out. Method statements shall be prepared and submitted to the Engineer for approval for each facet
of the work at the start of construction, within time scales specified. The onus lies with the Contractor to ensure that the information is acquired,
and associated activities are completed expeditiously in order to avoid any delays in the commencement, continuation and completion of the
required works.
Unless otherwise specified or provided for in the Contract Documentation no permanent works shall be commenced until the Engineer’s approval
has been obtained.
Where the method statement/s are not approved due allowance shall be made for obtaining alternative materials, resubmissions and redesigns,
all to the required/approved standards, methods and practises in attending to these requirements. Particular attention shall be paid to the early
submission of materials-, concrete- and grout mix designs where parameters at various ages may be specified. No consideration for extension
of the contract period will be entertained for delays incurred in meeting these requirements.
Trials, to demonstrate and confirm the efficacy of the Contractor’s proposed work method, shall be undertaken at the onset of construction, before
production work commences. Based on the outcomes of these trials, the Engineer may require changes to be made to the relevant method
statement(s). Once approved in writing by the Engineer, these shall become the method statements in accordance whereby the relevant portion
of the works shall be executed thereafter. Notwithstanding, the Engineer may require revision from time to time if circumstances during construction
arise which warrants change.
The Contractor shall notify and submit any proposed amendments to an approved method statement for any section of the work to the Engineer
for his re-approval at least 2 weeks prior to his intention to commence with that section of the work. The Contractor shall not deviate from the
approved method statement(s) for any section of the works, before the proposed changes have been submitted to the Engineer for scrutiny and
procedural compliance and written approval has been obtained.
The Contractor shall remain responsible for all work-methods, materials, plant and equipment used, notwithstanding acceptance by the Engineer.
b) Handling storage and protection of materials delivered to site
During transit, delivery and prior to installation all proprietary developed mitigation products and anchorages shall be protected against any form
of damage or permanent deformation whatsoever. The materials shall be stored in a dedicated, weather-proof shed(s), away from the works area
to minimize the potential for damage. All materials shall be stored well clear of the ground on appropriate stable trestles approved the Engineer.
No materials shall be delivered to site before the requisite facilities to receive are in place and approved in writing by the Engineer.
The Contractor shall notify the Engineer once the materials are received on site and shall inspect these together with the Engineer to both verify
that the delivery correctly reflects the materials ordered, that all the requisite components of each and every installation have been received and
that these have not been damaged during transit and/or delivery in any way. The Contractor shall replace any incorrectly delivered; short delivered
or damaged components which cannot be repaired to the requisite standard as soon as possible to minimize potential delays to the construction
programme.
The Contractor shall not proceed with the translocation of any of these materials to the works area for installation before the inspection is complete
and sign off by the Engineer is conformed in writing.
The Contractor shall ensure that the method of translocation and handling of these materials from storage to installation, as well as during the
installation is such that they are not damaged in anyway whatsoever.
All damaged materials which cannot be repaired to the requisite standard shall be replaced at the Contractor’s cost.
c) Traffic control and lane closure
Traffic control, lane closure, safety, cordoning off of the works area and providing access to the Engineer for setting out and inspections are the
responsibility of the Contractor and the minimum requirements shall be as specified in the Contract Documentation. No work shall proceed until
such time as the Engineer has approved all the required measures.
Prior to the commencement of any slope protection work on any of the slope and cuttings the Contractor shall ensure that the specified traffic
barriers, stop and go and all other specified traffic control measures, including road closure barriers as may be specified and required are in place
and have been approved by the Engineer.
Total road closures may be required where fragments of rock could impact on the lane reserved for use by public traffic and the Contractor shall
be equipped for and remain on standby at least 30 min prior to the intended opening of the road to clear the lane of such fragments of rock and
other debris. The Contractor shall also within the time of road closure, complete any temporary repairs to the road surface to the specified and/or
standard required by the Engineer to make it trafficable and safe.
d) Cordoning off the works area
The work areas requiring scaling and the drop zones and run-out areas of falling rock shall be suitably cordoned off and barricaded to ensure that
falling rock debris is channelled and/or contained within restricted areas. If space is limited, this may require temporary rockfall barriers of adequate
height and capacity to be installed.
Access for the Contractor’s plant, equipment, materials and other resources to and from each of the work areas demarcated by the barriers shall
be strictly in accordance with the specific requirements set out in the Contract Documentation.
e) Protection of the works, road pavement, infrastructure and furniture and accessories
Any rock or other material dislodged by barring down operations shall be brought onto the surface of the Contractor’s work area without causing
any damage to road furniture, infrastructure or construction work in progress or already complete. The Contractor shall design and provide the
requisite protection works for each section of the work and contemplated activity.

f) Access for inspections, mapping, setting out and testing
The Contractor shall at all times provide suitable, stable and safe access and allow the requisite time in his programme for all necessary
inspections, mapping and setting out by the Engineer and the testing of the installed rock reinforcement and support elements of the mitigation
installation(s). This access shall consist of either crane suspended baskets, raised platforms or ladders.
The Contractor shall provide the Engineer and his staff with the requisite compliant safety harnesses and hard hats for these inspections. These
shall be clean, free of dirt and grime and in perfect working order when presented to the Engineer or his staff.
The Contractor shall suspend all other work as agreed with and approved by the Engineer on or in the immediate vicinity of the area being
inspected, mapping or whilst setting out is taking place. The Contractor shall allow for the cost and time for this potential disruption to his work
programme.
Setting out of the installations and/or components is unlikely to be undertaken as a once off single operation. The initial setting out shall be as
per the design layout specified in the Contract Documentation and/or drawings. However thereafter site conditions may dictate that adjustments
and alterations are required which must be referred to the Engineer for his consideration and amendment. The Contractor must therefore expect
and allow in his tender rates and programme for additional setting out exercises to be undertaken.
A12.9.7.2 Process
a) Rock Barring
This part of the specification covers the operations involved in the barring down and cleaning of loose rock from the faces of the various cuttings
and removing the material so produced to an approved disposal site. It also covers the inspections to be carried out prior to and after the
completion of barring down operations.
The Contractor shall make available equipment as required and approved by the Engineer together with a qualified operator to bring the Engineer’s
representative to within at least half a metre of any part of the surface of the cut face or slope requiring assessment. The Engineer’s representative
will undertake a detailed inspection of the rock surface before the barring down operations commence to determine to extent of barring required
and if necessary subsequent intermittent inspections to instruct the Contractor accordingly. All costs and delay incurred in providing this access
must be allowed for in the rates and programme for barring.
The Contractor shall have on site all the necessary equipment, plant materials and personnel required to gain access to and dislodge all rock
identified for barring down and to do so in compliance with all statutory and other requirements pertaining to matters regarding safety of personnel
and the general public.
All barring down shall be undertaken judiciously, in a controlled manner, and strictly as directed by the Engineer’s representative. It may therefore
be that in certain instances key blocks which are potentially unstable be instructed to be left in place and anchored back, or in the event of very
loose of friable ground, that no further removal takes place and that the ground instead be stabilised by a suitable revetment and/or bolts as part
of the mitigation works.
The Contractor will be required to traverse every square metre of the rock surface requiring stabilisation/treatment and attempt to bar down all
hollow sounding rock surfaces identified by tapping with a pinch bar or other approved method. The Contractor will continue with the barring down
to the satisfaction of the Engineer and he may be required to re-attempt to bar down sections of rock or specific rocks previously attempted as
may be required by the Engineer.
All loose material resulting from the barring down and cleaning operations shall be loaded and transported to the approved disposal site.
Once the mitigation measures are installed, the slopes in question shall be cleared of all loose fist size rock and greater by further scaling where
so required and then finally blowing it clean with the requisite number of passes of a high pressure jet of compressed air together with a high
pressure jet of water, if required.
Cleaning shall be undertaken from the top down to ensure that all loose rock and debris is systematically removed from the rock surfaces and
ledges and is not re-deposited on an adjacent section of rock surface previously cleaned. The Contractor shall remove any rock or debris so re-
deposited at no extra cost and all rock surfaces shall be cleaned to the satisfaction of the Engineer.
A final inspection and sign off by the Engineer’s Representative is required once the barring and cleaning is complete to confirm that the work has
been undertaken to the Engineers’ satisfaction and required standard.
b) Anchoring of slope protection installations
The anchoring required for the various slope protection installations shall be of the type, detail and at the locations provided in the relevant design
layout drawings and Contract Documentation or as might be modified and instructed by the Engineer for the wire mesh rockfall revetments, or in
accordance with the guidelines and requirements of the product and installation manuals in the case of catch fences, shallow landslide barriers
and debris flow barriers.
The Contractor shall initially set-out the design layout of the mitigation works which mainly entails the layout of the anchors of all the installations
as per the approved construction drawings, making use of approved survey methods specified and/or instructed by the Engineer. This setting out
will be inspected by the Engineer to confirm that the intended layout is to his satisfaction. The Engineer may require adjustments to the position
of certain elements of the installation or may decide that the alignment and location requires adjustment to better accommodate the topographical
or other physical constraints. The Contractor shall assist and co-operate with the Engineer in all respects in finalising the setting out and must
allow for this in his rates and construction programme.
Drilling and grouting of the anchors shall be undertaken in accordance with the requirements as specified for rock dowels in Section A12.2, to the
type, diameter, orientation and depth specified.
Holes shall be accurately set out and collared to within 75 mm of the required position for the wire mesh panel installations, and the upslope
support cables of the posts of catch fences, shallow landslide fences and debris flow fences, and the lateral anchors of the catch fences and
shallow landslide fences.
Accurate and relevant drilling templates, agreed to and approved by the Engineer, will be required for drilling the anchors of all post baseplates
as well as the anchors of the lateral support ropes of the debris flow fences. Collaring the holes is strictly dictated by the specific anchorage
arrangement(s) and no deviation from the template will be allowed. Holes that are found to have been collared and/or drilled deviant from the
template will be grouted and re-drilled once the grout reaches a minimum strength of 10MPa.
The Contractor shall control the drilling operations by the use of proper equipment and techniques to ensure that no holes deviate more than 2 %,
once collared, from the required orientation.

Holes, which upon orientation measurement, deviate more than 2 % from the required orientation shall be filled with inert material or grouted as
instructed by the Engineer, abandoned and a new replacement hole shall be drilled at the Contractors’ cost.
c) Installation of draped wire mesh rockfall netting revetments
The revetment shall be installed in accordance with the details provided in the design layout drawings and specifications or as might be modified
and instructed by the Engineer.
Draped wire mesh rockfall netting shall be anchored at the top of the slope or cutting. The rockfall netting is continuously attached and tied off to
a top longitudinal wire rope cable of specified type, diameter and strength, set back a minimum of 2,0 m from the crest of the cutting or as specified
in the Contract Documentation and/or the drawings. The top longitudinal wire rope cable is in turn restrained and connected to top anchors of
specified type, capacity, length and spacing. The top longitudinal wire rope cable may either be attached directly to the top anchors or set off and
connected by way of short transverse wire rope cables from each top anchor. The top longitudinal wire cables are interrupted and tied off to
intermediate top lateral anchors at 30 m intervals, or as specified in the Contract Documentation and/or the drawings. The top longitudinal wire
rope cables are tensioned as specified or indicated on the construction drawings to limit its sag between adjacent anchors.
Drape mesh may either be non-restrained but weighted down at the base of the slope or cutting to guide and restrict the exit of rockfalls to within
a defined drop zone, or they may be tied off to a longitudinal bottom wire rope cable of specified type, diameter and strength, restrained by bottom
anchors of specified type, diameter and spacing. The bottom cable is looped, typically one meter in diameter at regular intervals, which once
released allows the cable to be pulled away from the bottom of the slope or cutting to allow the periodic release and removal of trapped debris.
d) Installation of anchored wire mesh rockfall netting revetments
The revetment shall be installed in accordance with the details provided in the design layout drawings and Contract Documentation or as might
be modified and instructed by the Engineer.
Anchored wire mesh rockfall netting is affixed to the face of the slope or cutting by anchoring with rock dowels/soil nails which protrude through
the netting and are generally installed in accordance with a fixed grid pattern. The installation of the rock dowels/soil nails prior to the placement
of the netting is preferred as it affords the least opportunity for damaging the netting. If the anchors are to be placed after the rockfall netting has
been draped over the slope, special care and precautions need to be taken to ensure that the netting and its galvanic coating is not damaged or
coated with spills of cement grout by the subsequent drilling and grouting activities.
The rock dowels are fitted with clawed/spiked face plates and nuts, which grip the netting and when tightened and torqued up pull the netting
down tight against the ground surface. In the case of soft ground slopes the ground immediately around the proximal end of the anchor shall be
excavated to create a small depression/hollow. Torqueing must continue to pull face plate and netting into the ground. Anchored mesh
installations are designed to function as a system in that the strength of the mesh, diameter/capacity and spacing of the anchors are matched to
provide the required stability. In this manner a number of permutations and combinations of meshes of various strength, anchor capacity and
spacing may be identified to achieve the same end result from which the optimal economic combination may be identified.
Anchored Mesh/Netting revetments are tied-off by boundary ropes, setback two mesh apertures along the perimeter of the revetment. The
boundary ropes are clipped onto the netting and are tensioned and tied-off on external anchors to ensure that all loose blocks are contained by
the netting and do not slip out.
e) Installation of catch fences shallow landslide fences and debris flow fences.
The installations shall be installed in keeping with the details provided in the design layout drawings and Contract Documentation or as might be
modified and instructed by the Engineer.
The installation shall be undertaken strictly in accordance with the guidelines and requirements of the product and installation manuals provided
by the developer/supplier of the system. The Contractor shall adhere to and give the timeous notice as required in terms of Table A12.9.3-1 and
elsewhere in these specifications for all requisite hold points.
A12.9.8 WORKMANSHIP
A12.9.8.1 Acceptance of installations with proprietary supplied and designed products
All installations shall be finally inspected and signed off by a duly authorised representative of the approved specialist manufacturer of the
system(s) to verify that these have been installed in accordance with the requisite guidelines and standard(s) and will meet the performance
specifications of the system. Final payment for the installation(s) and the contract completion certificate shall not be issued if the completed
installation(s) have not been signed off as required in these specifications.
A12.9.8.2 Anchors
The quality control of the grouting of all anchors and load testing of the rock dowels and wire rope anchors shall be as per Section A12.2. All the
anchors supporting the top longitudinal wire rope cables of the drape mesh revetments and all wire rope anchors installed, for either catch fences,
shallow landslide fences or debris flow fences, shall be tested.
Where applicable, testing shall be undertaken prior to their possible encasement in concrete plinths.
The testing sequence and load limits shall be as for rock dowels/soil nails but using a specially adapted jack to accommodate the loop of the wire
rope anchor.
All tests shall be undertaken with the superintendence of the Engineer and the Contractor shall ensure that he adheres to the requisite hold points
specified in Table A12.9.3-1
The frequency of testing and applicable standards shall be as for Section A12.2.

B12.9 SLOPE PROTECTION MEASURES
CONTENTS
B12.9.1 SCOPE
B12.9.2 DEFINITIONS
B12.9.3 GENERAL
B12.9.5 MATERIALS
B12.9.8 WORKMANSHIP
B12.9.1 SCOPE
B12.9.2 DEFINITIONS
B12.9.3 GENERAL

B12.9.5 MATERIALS


B12.9.8 WORKMANSHIP

C12.9 SLOPE PROTECTION MEASURES
(i) Preamble
2.
pay items.
1,0 km.
C12.9.1 Barring down of rock surfaces within vertical height intervals (intervals stated) square metre (m2)
The unit of measurement shall be the square metre of rock barred down in accordance with the Engineer’s instruction. Heights shall be measured
from the outer edge of the road at the toe of the cutting. Barring down will be measured once only per area/section of the works instructed to be
treated irrespective of the number of times the Contractor is required to re-access the face of the cutting/slope to complete the work to achieve a
stable clean surface approved by the Engineer. The final measurement for payment will be made on the nett area of slope/cutting barred down.
The tendered rate shall include full compensation for access to the rock face, barring down of rock using suitable tools and equipment, adhering
to safety and other statutory precautionary measures, labour, plant (including specialised equipment), materials and all other necessary incidentals
to complete the works in accordance with the specifications and the Engineer’s instructions.

C12.9.2 Cleaning of rock surfaces by high pressure air and water jetting equipment within the square metre (m2)
vertical height intervals (categories stated)
The unit of measurement shall be the square metre of rock surface cleaned by high-pressure air and water jetting in accordance with the Engineer’s
instruction. Cleaning will be measured once only per area/section of the works instructed to be treated irrespective of the number of times the
Contractor is required to re-access the face of the cutting/slope to complete the work to achieve a stable clean surface approved by the
Engineer.The final measurement for payment will be made on the nett area of slope/cutting cleaned down.
The tendered rate shall include full compensation for access to the rock face, adhering to safety and other statutory precautionary measures,
labour, plant (including specialised equipment), materials and all other incidentals necessary to complete the works in accordance with the
specifications and Engineer’s instructions.
Heights shall be measured from the outer edge of the road at the toe of the cutting.
C12.9.3 Disposal of barred down and accumulated debris cubic metre

kilometre (m3.km)
The unit of measurement shall be the cubic metre of debris loaded at the toe of the cuttings resulting from the barring down and/or cleaning of the
rock surfaces hauled over the approved distance to the approved disposal site. The debris to be removed and measured under this item shall
also include existing debris which has accumulated at the toe of the cutting over the years.
The volume shall be equal to 70 % of the loose struck volume measured in trucks in the case of soil and gravel material, and equal to 60 % of the
loose struck volume in trucks in the case of hard material consisting predominantly of particles of which the maximum dimension exceeds 100
mm.
The tendered rate shall include full compensation for loading and disposing of all material to an approved disposal site and placed and finished in
accordance with the Engineer’s requirements.
C12.9.4 Supply and install wire mesh rockfall netting within vertical height intervals (intervals square metre (m2)
stated), galvanic requirements, roll width, wire thickness, tensile strength, weave, aperture,
PVC coating and/or colouring indicated
The unit of measurement shall be the square metre of mesh wire mesh rockfall netting placed, secured and anchored in accordance with the
design layout drawings and the specifications of the approved specialist manufacturer of the system(s). The final measurement for payment will
be made on the nett area of mesh installed. The requisite overlaps and joints required to ensure full effective coverage of the slope/cutting shall
not be measured.
The tendered rate shall include full compensation for the procuring mesh, joining mesh rolls to create continuous netting and placing mesh on the
slopes and cutting, inclusive of all labour, materials, catch fence components including all clips, clamps and shackles and all other incidentals at
the locations required in accordance with the Engineer's instructions including the requisite process control testing, testing and sign off certificate
by the authorised representative of the approved specialist manufacturer of the system(s) if relevant. The tendered rate shall include full
compensation to the Contractor to assist and co-operate with the Engineer in all respects in finalising the setting out of the design layout, including
the individual elements of the installation.
Measurement and payment for all the anchoring of rock anchors, dowels and wire rope anchors shall made in Section A12.2.
C12.9.5 Supply and Installation/erection of catch fencing (galvanic requirements, type, height, metre (m)
length and energy rating in kJ and location of fences indicated)
The unit of measurement shall be the linear metre of catch fence supplied and erected in accordance with the design layout drawings and the
specifications of the approved specialist manufacturer of the system(s). Separate rates are required for each standard length class intervals,
namely, 0-10 m; >10 m – 20 m; >20 m- 30 m; >30 m – 40 m; >40 m – 50 m; >50 m – 60 m. The rates for each class length shall distinguish
between fence height and energy rating.
The tendered rate shall include full compensation for the procuring and erecting of the catch fence system, inclusive of all labour, materials, catch
fence components including all anchors, clips, clamps and shackles and all other incidentals at the locations required in accordance with the
Engineer's instructions including the requisite process control testing, testing and sign off certificate by the authorized representative of the
approved specialist manufacturer of the system(s).The tendered rate shall include full compensation to the Contractor to assist and co-operate
with the Engineer in all respects in finalising the setting out of the design layout, including the individual elements of the installation. The rate shall
make provision for a standard anchor length of 3,0 m for all threadbar and wire rope anchors.
C12.9.6 Supply and installation/erection of additional anchor lengths for catch fences metre (m)
(differentiate between threadbar and wire rope anchor for different diameters)
The unit of measurement shall be the linear metre of anchor length in addition to the standard 3m length of relevant anchor allowed for and priced
in item C12.9.5. The need for the additional anchor length shall be as required by the design to match the ground conditions and as instructed
and approved by the Engineer. In the event that the diameter and/or type of anchor provided for in the measurement item above does not match
that used for the fence offered by the Contractor, he shall indicate the requisite diameter and/or type of anchor(s).
The tendered rate shall be inclusive of all the additional compensation for the additional drilling, cleaning drill holes, procuring, corrosion protection,
installing and grouting, all labour, materials and all other incidentals required to complete the work in accordance with the Contract Documentation
and the Engineer’s instructions. All pull out test requirements and costs are deemed to be included in the tendered rate for this item and no extra
payment will be made in this regard.

C12.9.7 Gap filling under the catch fences (energy class stated) square metre (m2)
The unit of measurement shall be the square metre of fencing installed for gap filling as instructed by the Engineer.
The tendered rate must shall be inclusive of all the additional costs that will be incurred in the erection of the gap closures below the catch fences,
including anchors/pins required in accordance with the approved specialist manufacturer’s and the Engineer’s requirements.
C12.9.8 Supply and installation/erection of shallow landslide fencing (galvanic requirements, metre (m)
type, height, length and rating and fence length class interval
The unit of measurement shall be per linear metre of shallow landslide fencing supplied and erected in accordance with the design layout drawings
and the approved specialist manufacturer’s specifications. Separate rates are required for each standard class length intervals, namely, 0-10
m;>10 m – 20 m;>20 m- 30 m;>30 m – 40 m;>40 m – 50 m;>50 m – 60 m. The rates for each class length shall distinguish between fence height
and rating.
The tendered rate shall include full compensation for the procuring and erecting of the shallow landslide fence system, inclusive of all labour,
materials, catch fence components including all anchors, clips, clamps and shackles and all other incidentals at the locations required in
accordance with the Engineer's instructions including the requisite process control testing, testing and sign off certificate by the authorised
representative of the approved specialist manufacturer of the system(s). The tendered rate shall include full compensation to the Contractor to
assist and co-operate with the Engineer in all respects in finalising the setting out of the design layout, including the individual elements of the
installation. The rate shall make provision for a standard anchor length of 3,0 m for all threadbar and wire rope anchors.
C12.9.9 Supply and install additional anchor lengths for shallow landslide fences (differentiate metre (m)
between threadbar and wire rope anchor for different diameters
The unit of measurement shall be the linear metre of anchor length in addition to the standard 3,0 m length of relevant anchor allowed for and
priced in item C12.9.8. The need for the additional anchor length shall be as required by the design to match the ground conditions and as
instructed and approved by the Engineer. In the event that the diameter and/or type of anchor provided for in the measurement item above does
not match that used for the fence offered by the Tenderer, the Tender shall indicate the requisite diameter and/or type of anchor(s).
C12.9.10 Gap filling under the shallow landslide fences (fence rating indicated) square metre (m2)
The unit of measurement shall be the square metre of fencing installed for gap filling as instructed by the Engineer.
The tendered rate shall allow for all the additional costs that will be incurred in the erection of the gap closures below the shallow landslide fences,
including all anchors/pins required in accordance with the approved specialist manufacturer and the Engineer’s requirements.
C12.9.11 Supply and installation/erection of debris flow fencing (galvanic requirements, type, metre (m)
rating and location for each numbered fence indicated)
The unit of measurement shall be the running length in metres for each specific fence, measured for supply and delivery to site as required in
accordance with the design layout drawings and the approved specialist manufacturer’s specifications.
The tendered rate shall include full compensation for procuring, corrosion protection, all labour, materials, components including all anchors, clips,
clamps and shackles and all other incidentals required to provide the relevant Debris Flow Fence components at the locations requiredincluding
the requisite process control testing, testing and sign off certificate by the authorized representative of the approved specialist manufacturers of
the system(s). The tendered rate shall include full compensation to the Contractor to assist and co-operate with the Engineer in all respects in
finalising the setting out of the design layout, including the individual elements of the installation. The rate shall make provision for a standard
anchor length of 3,0 m for all threadbar and wire rope anchors.
C12.9.12 Supply and install additional anchor lengths for debris flow fences (differentiate metre (m)
between threadbar and wire rope anchor for different diameters)
The unit of measurement shall be the linear metre of anchor length in addition to the standard 3,0 m length of relevant anchor allowed for and
priced in item C12.9.11. The need for the additional anchor length shall be as required by the design to match the ground conditions and as
instructed and approved by the Engineer. In the event that the diameter and/or type of anchor provided for in the measurement item above does
not match that used for the fence offered by the Tenderer, the tender shall indicate the requisite diameter and/or type of anchor(s).

D12.9 SLOPE PROTECTION MEASURES
CONTENTS
D12.9.1 SCOPE
D12.9.2 GENERAL
D12.9.1 SCOPE
D12.9.2 GENERAL
specified in the Contract Documentation. Unless otherwise specified, all proprietary materials shall be used and placed in strict accordance with
the relevant manufacturer's current published instructions.









12.10 HARD EXCAVATION BY BLASTING
CONTENTS
A12.10.1 SCOPE
A12.10.2 DEFINITIONS
A12.10.3 GENERAL
A12.10.5 MATERIALS
A12.10.8 WORKMANSHIP

A12.10 HARD EXCAVATION BY BLASTING

A12.10.1 SCOPE
This Section covers all aspects of the work and associated operations for controlled drilling and blasting in hard material.
The responsibility for planning and conducting hard excavation by blasting in accordance with the requirements of these specifications, rests solely
with the Contractor.
Controlled blasting techniques are mandatory for all excavations to limit and/or avoid as required, potential damage to the remaining rock mass,
excavated surfaces, infrastructure and property resulting from rock blasting activities. They also minimize fly rock along active routes, within
urban areas and within the proximity of any infrastructure or property that could be damaged.
The requirements given hereunder supplement that given in Clause A1.2.7.5 of Chapter 1 and are complimentary to Sections A4.1 and A4.2 of Chapter
4 and any other Chapters that address the excavation of hard materials by blasting. The breaking down and/or crushing or crushing and screening of
blasted rock is covered in Chapter 4.
The following definitions, terms, works and expressions are applicable to this section. These are not exhaustive and merely represent a selection
used in the field of controlled rock blasting. Accordingly, these do not limit the scope of the blasting that may be required to meet the outcomes
and objectives set out in the Contract Documentation.
Controlled blasting - includes the use of special techniques, measures, procedures and for using explosives and ancillary materials specially
manufactured for this purpose in order to ensure that the required objectives are met without damage to person, property or the works.
Specified excavation or payment line - means the excavation profile given on the drawings or determined by the Engineer for the works, within
which no unexcavated or loose material shall occur after the excavation is complete except as allowed within the specified tolerances. It is also
the line to which payment for excavation will be measured and made. No additional payment will be made for any material excavated or removed
beyond this line unless the Contractor can demonstrate that the over excavation was not attributable to negligence or poor workmanship on his
part and was due to adverse ground conditions.
Pre-splitting - entails blasting utilising closely spaced, parallel drilled holes of appropriate diameter along the intended final excavation surface.
These holes may either be vertical or drilled at the inclination specified to establish the specified line in the Contract Documentation and/or shown
on the construction drawings. Pre-split holes are charged with a reduced amount of explosive than those for bulk blasting which is decoupled
from the wall of the blast hole and may include spacing the explosive charges along the length of the hole if required, i.e. deck charging. These
holes are detonated simultaneously, prior to the main bulk blast, to create a single, clean, continuous fracture plane in the rock along the line of
drilled holes, thereby creating the final permanent excavation surface with negligible or very limited damage.
Smooth blasting - entails drilling a line of closely spaced parallel holes along the intended final excavation surface, with a suitable burden/spacing
ratio and loading all the holes lightly with an appropriate amount of explosive, including decked charging if required. These charged holes are
detonated, as part of the main blast, but as the last row to be fired, thereby creating the final permanent excavation surface with negligible or very
limited damage.
Line Drilling - is a method of overbreak control which uses a series of closely spaced holes that are not charged to create a final excavated
surface with negligible damage.

Cover blasting - entails covering the blast area with material or mats, loading holes lightly with an appropriate amount of explosive and with a
suitable burden/spacing ratio to control fly-rock.
Cushion/Buffer Blasting - comprises the separate removal of a protective zone of rock which has been purposely left within the specified limits
of excavation for flat areas and shallow slopes. Drilling for cushion blasting shall consist of a regular pattern of holes at appropriate spacings and
angles and to accurate depths.
The holes shall be lightly charged and detonated in relays to lift the rock progressively to form the final excavated surface without shattering the
surrounding rock.
Air Blast and Over Pressure - refers to the shock wave travelling through the air resulting from the detonation of explosives. It is measured in
decibels.
Back break - is the rock broken beyond the limits of the controlled perimeter blast line. Back break may result from blast damage and/or from
adversely oriented geological structure within the rock mass.
Burden - is the distance between an explosive charge and the nearest free face in metres. In multiple row blasting it is also the distance between
two adjacent parallel rows of holes to be fired in succession. Where a free face is available and used for blast design, the burden is the distance
between the toe position of the first or front line of the drill holes and the free face.
Explosive Charge - is the quantity, ie weight/mass of explosive to be detonated, measured in kilograms.
ANFO – Ammonium Nitrate Fuel Oil - is a bulk explosive comprising porous prilled ammonium nitrate with about 6% fuel oil (diesel or kerosene)
added to curb moisture absorption.
Column Charge - is the length of an explosive charge including any portion of hole drilled below the design grade, loaded in the drill holes to be
detonated during the blast.
Cut-off - is a portion of an explosive charge that has failed to detonate, either due to the initiation system failing to propagate the whole blast or
due to a cut-off in the system as a result of flyrock, ground movement, or system failure.
Decoupling - is the use an explosive charge having a smaller diameter than the diameter of the blast hole it occupies.
Bulk blasting - is the excavation of large volumes of material in a basting action.
Controlled Perimeter Blasting - comprises presplitting, smooth blasting, line drilling and cushion blasting techniques to minimize blast vibrations and
to optimally limit potential damage and back break to final permanent excavation faces.
Delay blasting - is the use of delay detonators or connectors to separate and delay the detonation of explosive charges in a single blast according
to a defined time sequence. This limits the amount of explosive detonated instantaneously and thereby limits the level of blast vibrations generated.
Detonation pressure - is the pressure created in the reaction zone of the detonating explosive.
Drill cuttings - are the fine chippings of rock material which are produced in percussion drilling of the blast holes and blown out as the hole
advances.
Explosives - are chemicals and chemical mixtures which, when properly initiated, are rapidly converted into gases at high temperature and
pressure as the detonation wave propagates through the explosive column. Unconfined, a litre of explosive will expand to around 1 000 litres in
milliseconds. Together with the shock wave of detonation, this results in extremely high breaking stresses in rock.
Free face - is any unconfined rock surface exposed to air – either natural or created by blasting, located some distance from the blast hole, which
reflects the compressional blast induced shock wave, turning it into a reflected tensional wave front which results in breakage and fragmentation
of the rock mass.
Flyrock - comprises rock fragments propelled through the air by the force of the explosion from a blast.
Fragmentation - is a measure to describe the particle (fragment) size distribution of the rock mass broken (fragmented) by the blast. It is normally
a measure of the extent to which the rock is broken into small pieces by a primary/bulk blast.
Ground vibration - is the ground movement caused by the stress waves emanating from a blast.
Half barrel - is the rounded intact rock surface of the blast hole formed by the drilling process which remains sculpted behind on the blast-created
rock surface.
Initiation - is the act of detonating explosives by appropriate means.
Maximum Instantaneous Charge - is the mass of explosive detonated simultaneously, within a single delay interval, as part of a blast.
Overbreak - is the amount of rock broken and removed by blasting, and/or subsequent scaling, beyond the specified excavation limit/payment
line.
Peak Particle velocity (PPV) - is the maximum speed of movement in a given direction of a rock or soil mass recorded as mm/s.
Secondary blasting - is blasting undertaken to further breakdown excessively large rocks produced by a blast or re-blasting a portion of the rock
mass which did not breakout as required and which remained behind.
Spacing of blast holes - is the centre to centre distance between adjacent drill holes in the same row.
Stemming - is the portion of the blast hole packed with inert material above the charge so as to confine and retain gasses generated by the
explosion during detonation, thus improving the fragmentation process. Inert material used in the stemmed section of the blast hole is also referred
to as stemming.
Toes - occur at the lower part of the blast near the base of the blast holes and represent a mass of rock that is not broken out by blast. Toes may
be caused by misfires, cut-offs or an excessive toe burden. Toes generally require secondary blasting for removal.

A12.10.3 GENERAL
Implementation of controlled blasting techniques is mandatory for all excavations to limit and/or avoid as required, potential damage to the
remaining rock mass, excavated surfaces, infrastructure and property resulting from rock blasting activities. They also minimize fly rock along
active routes, within urban areas and within the proximity of any infrastructure or property that could be damaged.
Controlled blasting techniques include:
- Controlled Perimeter Blasting comprising presplitting, smooth blasting and line drilling and cushion blasting techniques to minimize blast vibrations
and to optimally limit potential damage and back break to final permanent excavation faces.
- Controlled bulk blasting, which limits the mass of explosives detonated simultaneously per delay in the body of the ground to be excavated, away
from the perimeter of the excavation. This is required to reduce ground vibrations to the specified minimum at potentially vulnerable/strategic
locations within the zone of influence of the blast. Controlled bulk blasting may affect fragmentation of the rock adversely and could thereby
impact on the cost of the loading, hauling and crushing of the rock, all of which the Contractor shall allow and cater for in his programme and
rates for undertaking these works.
- Providing a buffer zone of limited width, of reduced spacing, burden, charge mass and other special measures, for blasting the ground between
the controlled perimeter blast, and the controlled bulk blast. The buffer zone may either be detonated as part of the controlled bulk blast or as a
separate blast, subject to the approval or, instructed by the Engineer.
- Cover blasting shall be used in the vicinity of overhead services (e.g. telephone and power lines) where overhead services may be damaged or
affected by blasting activities. The cover blasting shall be such that it sufficiently protects overhead services to prevent any damage to such
services.
Controlled blasting shall only be undertaken by suitably experienced and equipped blasting Contractors with proven track record of having
successfully undertaken controlled blasting techniques. The works shall be managed and controlled on an on-going daily basis by a works
manager/blasting Engineer with a proven track record in the use of controlled blasting techniques.
In the event that the Contractor does not have the necessary experience he shall sub-contract this work to a suitably qualified, experienced and
appropriately equipped sub- undertaken controlled blasting techniques. The appointment of a suitable Sub-Contractor shall be subject to the approval
of the Engineer.
A copy of all certificates issued to workmen to permit them to undertake blasting, and to the Contractor to cover the purchasing, storage and transport
of explosives shall be handed to the Engineer before any blasting work is undertaken.
In the event where excavation is undertaken along an existing route which needs to remain operational, road closures are required during blasting
and immediately thereafter whilst clearing of blast debris, which might have landed on trafficked lanes, takes place. To limit the duration of total
road closure per blast, and hence time required to clear spoil and repair any road surface damage, only limited sections shall be blasted at a time.
This restriction may limit the Contractor’s activities and production, and the Contractor shall make due allowance therefore in his rates and
programme.
The work shall be programmed so as to minimise blasting adjacent to constructed sections of the Works.

The Contractor shall prepare detailed method statements for each facet of the work describing key aspects such as construction methodology, key
plant, materials, personnel as well as any programme constraints of the envisaged construction process. The Contractor shall follow published and
proven South African and International Industry Guidelines and Standards for controlled blasting techniques when preparing method statements
and designing the blast patterns.
These method statements shall be prepared and submitted to the Engineer for approval prior to commencement of the blasting activities within time
scales specified. The onus lies with the Contractor to ensure that the information is obtained and that associated activities are completed
expeditiously before blasting operations commence to avoid any delays in the commencement, continuation and completion of the required works.
Unless otherwise specified or provided for in the Contract Documentation no permanent works shall be commenced until the Engineer’s approval
of the relevant method statement. The Contractor shall, however, remain responsible for all work-methods, materials, plant and equipment used,
notwithstanding acceptance by the Engineer.The Contractor shall be required to carry out trial blasts to demonstrate that acceptable results will
be obtained. The trials will be used to determine the appropriate combinations of drill hole size, hole spacing, burden, explosive type and charge
level, detonating sequence and delays between individual holes or rows of holes to obtain the optimal desired outcome. Rock conditions may vary
from place to place and trial blasts are needed to enable adjustments to be made to drilling and blasting techniques and patterns for the relevant
conditions.
Trial blasts, shall further be conducted as deemed necessary and /or as ordered by the Engineer for each set of rock mass conditions/differing
ground types.
Blasting for confined/restricted excavations requires separate trial blasts to be carried out, before productive work may commence for these
excavations. These sections shall be identified and agreed jointly between the Contractor and the Engineer on site as part of the planning and
preparations for the commencement of the trial blasts. Other than in the instance of confined/restricted excavations the minimum length and
depth of each test section shall be about 20 m and 7,0 m respectively.
The test sections for the trial blasts must as far as possible be undertaken within the volume of the material to be excavated, provided that no
charge may be detonated closer than 10 m from any final permanent excavated surface. If this is not possible, a suitable location(s) within identical
ground conditions, as close as possible to the site, needs to be identified and agreed to.
Ground vibrations and the damage to the rock surfaces and/or structures and infrastructure noted during the trials will be used to establish the
total safe allowable explosive charge to be detonated per delay which the Contractor will not be allowed to exceed for subsequent production
blasting.
The quality and adequacy of the results obtained will be jointly assessed by the Engineer and the Contractor and the relevant method statements
amended as agreed by both parties Once approved in writing by the Engineer, these shall become the method statements in accordance whereby
all blasting shall thereafter proceed for the relevant set of rock mass conditions/ground types.

Notwithstanding, the Engineer may require revision and trial blasts from time to time if circumstances and/or ground conditions during construction
arise which warrants change. Trial blasts need to be undertaken and completed and the results accepted by the Engineer at least 2 weeks prior
to the commencement of productive work on the particular portion of the contract.
All successful trial blasts approved by the Engineer will be measured and paid for under the relevant drilling and blasting rates. No extension of
time or additional time, whatsoever, will be granted to the Contractor for the disruption or for additional associated costs for carrying out trial blasts.
The Contractor shall make due allowance therefore in his programme. Allowance shall also be made for allow for the Engineer’s
assessment of constructed works, procedures followed, and materials and plant utilised and test data. Production work shall not be
permitted until it is shown and accepted by the Engineer that the Contractor possesses the necessary experience, plant and equipment to
carry out the works as specified in the Contract Documentation.
The supply of any information to the Engineer in respect of the controlled blasting techniques does not relieve the Contractor of his
responsibilities under the Contract
A12.10.3.2 Materials, design and process approvals

The Contractor shall provide comprehensive details of all materials and equipment to the Engineer for his acceptance/approval as provided for in
the Contract Documentation within the time frames indicated in Table A12.10.3-1. Where relevant, evidence of compliance with the appropriate
specifications shall be provided.
Due allowance shall be made for obtaining such information, resubmissions and re-designs, all to the required/approved standards, methods and
practices in attending to these requirements. No consideration for extension of the contract period will be entertained for delays incurred in
Table A12.10.3-1: Approval requirements
Clause Approvals required Period
A12.10.3 Method Statements: Engineers approval of:
2 weeks prior to initial trial blasts for the

Method Statements and Blast Patterns for initial trial blasts.
various sections
A12.10.7.1a)
Submission of revised Method Statements and Blast Patterns 1 week prior to production drilling and
for production blasting following satisfactory trials. blasting.
A12.10.5 Materials approvals: Engineers approval of:

A12.10.5.1
Explosive type, detonators and initiation system and stemming
A12.10.5.2 2 Weeks before trial blasts.
proposed by Contractor
A12.10.5.3
A12.10.7 Process approvals: Engineer’s approval of:

A12.10.7.3 a)
- Preparation and clearing site for each and every blast. One day before setting out.
A12.10.7.3 b) - Mark-up and setting of blast holes One day before drilling.
A12.10.7.3 b) - Perimeter Blast hole orientation survey One day prior to charging.
A12.10.7.3 c) - Depth, spacing and approval of drilled holes ready for charging One day prior to charging.
A12.10.7.2 c) Engineer approval that equipment for vibration and over No charging up or blasting pending
pressure monitoring equipment is in place and in working order approval.
Prior to continuing with drilling and
A12.10.7.3 f) Post blast Inspection and approval by the Engineer blasting
Prior to drilling and blasting for next
Assessment of preparatory works rock support bench
Disputes/variations
A12.10.8.1 Engineer/Contractor disagreement on an outcome of any blast Works stopped pending receipt of
independent specialist’ report
A12.10.7.3 f) Submission of a revised blast pattern when variation in ground Engineer’s approval required before
conditions is encountered further drilling and blasting
A12.10.7.3g) Contractor to submit Required Records timeously Drilling and Blasting shall only
commence receipt of the required
records
The Contractor shall comply with the above requirements and shall furthermore give the Engineer at least 24hrs written notification in respect of
requests for required inspection(s).

The Contractor shall, notwithstanding his responsibility to design all the blasting required for the contract as per Clause A12.10.4: Design by
Contractor and /or in the Contract Documentation, comply with the requirements regarding the timeous provision of and the Engineer’s approval
of method statements, materials and processes as detailed above, in Table A12.10.3-1: Approval requirements, and as further specified in these
specifications. This is to ensure that the appropriate processes and materials are employed and, in view of the permanence of the results, the
avoidance of undesirable outcomes.
A12.10.3.3 Notification of blasting to all relevant and affected parties

The Contractor shall give 7 days provisional written notice to all parties engaged on site, relevant authorities and the media of any blasting to be
undertaken. The Contractor shall thereafter confirm this provisional notification as a final notification in writing to the relevant and affected parties
24 hours before it is to be carried out. The notification shall show the location of and the intended time of each blast and the contact details and
name of the licensed blaster and shift foreman responsible.
Any delay or postponement of any blasts after notifications have been issued shall be conveyed in writing to all relevant and affected parties
immediately and if relevant a revised date and time advised.

The Contractor shall design all blasting required for the contract. All blasting shall be carried out in accordance with the requirements of these
specifications. A suitably qualified and experienced specialist in the field of controlled blasting, the credentials of whom have been accepted by
the Engineer, shall sign off on the method statements and shall guide the design of each blast.
The approved specialist shall visit the site of the works on a regular basis and at appropriate times to appraise himself on an on-going basis of
the nature and quality of the Contractor’s work and the outcome of the blast results. He shall submit a written report on each and every visit
undertaken, the table of contents of which will be agreed with the Engineer on site at the commencement of the contract or variations as may be
agreed. The report will be submitted via the Contractor to the Engineer within one week of the site visit. The approved specialist shall attend all
technical meetings which deal with any aspect relating to drilling and blasting on the contract when required.
If a suitably qualified and experienced specialist is not in the full time employ of the Contractor, the Contractor shall appoint such a specialist at
his own cost. All costs associated with procuring the services of the approved blasting specialist and the inputs required will be deemed to be
covered in the Contractor’s rates for undertaking the works.
The Engineer may also in turn appoint a specialist of his choice to undertake independent reviews of the Contractor’s blast designs and method
statements. Acceptance by the Engineer or the independent specialist employed by the Engineer of any method statements, blast designs or
proposals made by or on behalf of the Contractor, does not relieve the Contractor of his responsibilities and obligations under the contract.
A12.10.5 MATERIALS
A12.10.5.1 Explosives
All explosives proposed to be used by the Contractor are subject to acceptance by the Engineer. The explosives shall be of such quality and
power and shall be used in such locations as will achieve the desired result. The firing systems of blasts shall be controlled using reliable approved
delay detonators with the requisite degree of accuracy as per submitted design.
The Contractor shall submit comprehensive product data, specification and performance sheets produced and certified by the manufacturer and
relevant testing authority as might apply.
a) Controlled perimeter blasting
Only cartridge explosives, prepared specifically for pre-splitting and smooth blasting, packaged by explosive manufacturing firms and accepted
by the Engineer, will be permitted for use in controlled perimeter blasting. Appropriately spaced charges will be used in the case of presplitting.
No bulk explosives (such as ANFO) or pumped emulsions shall be used in pre-split, smooth and buffer blast holes.
Maximum diameter of explosives used in pre-split holes shall be less than half the diameter of the pre-split hole unless otherwise approved by the
Engineer.
Use of detonating cord may be used in certain applications for pre-splitting and smooth blasting if proven to be successful during trial blasts and
provided there are no environmental constraints on its use.
b) Controlled bulk blasting
Only standard cartridge explosives prepared and packaged by explosive manufacturing firms and accepted by the Engineer shall be permitted for
use in controlled bulk blasting.
No bulk explosives such as ANFO or pumped emulsions shall be used in controlled bulk blast holes.
A12.10.5.2 Detonators and initiation systems.

The desired outcome of controlled blasting, in particular where bulk blasting is combined with controlled perimeter blasting is critically dependant
on interactions between blast holes. All blasting shall be undertaken using delay detonators and may also require electronic initiation systems to
ensure that the required time interval between successive blast holes or rows of blast holes as per the designed sequence is achieved.
All detonators and initiation systems proposed to be used by the Contractor are subject to the approval of the Engineer. The Contractor shall
submit comprehensive product data, specification and performance sheets produced and certified by the manufacturer and relevant testing
authority as might apply.
Use of capped fuse and igniter cord shall not be allowed unless warranted under special conditions and shall be subject to approval by the
Engineer.
A12.10.5.3 Stemming
Stemming may only be used with the explicit written approval of the Engineer and the materials used shall be subject to the approval of the
Engineer. As a guideline, when in soft to hard rock, stemming shall consist of drill cuttings sourced from the drilling operation. In hard to extremely

hard rock, stemming shall be clean crushed rock with a mean size between 5 % and 10 % of blast hole diameter. The final selection of the
stemming material for each blast shall be subject to acceptance by the Engineer.

Drilling shall be undertaken by suitable drills rigs with adequate air flushing to remove drill cuttings efficiently and shall also be equipped with
effective dust suppressing and collecting equipment in urban environments.
All drill rigs and equipment shall be in good working order and capable of producing straight holes to required depths, dimensions, tolerances,
direction and inclination. Should the type of rig and/or equipment prove inappropriate for the requirements or conditions on site, these shall be
replaced by suitable equipment at the Contractor’s cost. The drill rig/equipment shall be able to complete all drilling operations, without loss of
direction or inclination, in all materials.
Drill bits to be used shall be selected to match the various rock types and rock mass conditions.

A12.10.7.1 General
a) Benched excavation and rock support
The excavation will be undertaken in a series of benches, as it becomes deeper, strictly in accordance to the lines and levels indicated on the
approved construction drawings. A maximum step out of 1,0 m to allow collaring of the drill rig, for drilling the following bench, will be allowed. In
this regard the Contractor shall scrutinize the approved construction drawings for constructability purposes prior to commencing with setting out
to ensure that the designed excavated profile can be achieved.
The Contractor’s attention is drawn to the possible restriction that rock support may need to be installed within the excavation cycle to stabilise
the rock cuttings, thereby interrupting normal production. In this instance the maximum depth of any blast will not exceed 10m, or such depth as
may be specified by the Engineer that can remain temporarily unsupported, whichever is the lesser.
Drilling and blasting of successive benches may not proceed until such time as the required rock support of the preceding bench has been installed
as is installed and tested as required by the Engineer. The Contractor shall allow for the costs and disruption in his rates and programme for
completing the drilling and blasting work.
b) Quality and finish of remaining rock
The Contractor shall ensure that his drilling and blasting techniques do not result in damage to permanent excavated surfaces. The Contractor
shall ensure that his blasting techniques will minimize blasting induced fractures or disturbance on the rock mass outside of the excavation line
so preserving the rock in the soundest possible condition. The required result of all controlled perimeter blasts is a uniform, clean, even undamaged
intact fracture surface without unwarranted overbreak and with the surface of the remaining half barrels of the drill holes intact, with no or minimal
fracturing visible within them, all within the tolerances specified.
The Contractor shall accept full responsibility for the quality of the remaining rock surface after a blast and shall make good, at his own expense
and as directed by the Engineer, any over-excavation and stabilisation of the rock necessitated by unwarranted blast damage. The Engineer may
instruct the Contractor to modify his method of drilling and blasting and to undertake further blasting trials if the required results are not obtained.
In the event of a disagreement between Engineer and Contractor regarding whether a given result rejected by the Engineer can or cannot not be
improved upon, all work on drilling and blasting shall stop in that section of the works. The Contractor and the Engineer shall agree upon a
recognised, suitably qualified and experienced independent specialist, who shall inspect the section of works in question and provide an opinion
whether:
- the results are either acceptable in the opinion of the independent specialist and the Contractor may continue, or,
- they can be meaningfully improved upon in the opinion of the independent specialist, in which case further trial blasts with revised patterns are
undertaken before production work may proceed.
The opinion will be binding on both parties. The works shall thereafter proceed in accordance with the revised blast pattern(s), procedures and
recommendations approved and made by the independent specialist.
All costs associated with procuring the services of the specialist will be for the Contractors’ account. The Contractor shall furthermore not be
entitled to any extension of time or extra costs caused by the delay or disruption in halting the work and obtaining the services of the independent
specialist.
c) Fragmentation
The controlled bulk blast shall be designed and optimised so that a minimum of oversize material is produced (a maximum particle size of 600mm).
The Engineer shall have the right to order the Contractor to adjust his blasting pattern and/or carry out secondary blasting or other measures to
reduce the size of the rock at his own cost, should he be of the opinion that the Contractor is not taking sufficient care to produce rock meeting
the requirements.
d) Stemming
No stemming of pre-split holes will be allowed, and these shall be fully vented, except where considerations of noise are overriding. Stemming
may only be used for other blasting methods with the explicit written approval of the Engineer.
The length of stemming required for controlled bulk blasting is generally significantly greater than that for bulk blasting and is dependent on rock
properties/conditions and degree of confinement and can vary from 20 to 60 times blast hole diameter. Other factors to be considered include:
- Rock conditions
- Blast hole diameter
- Bench height
- Burden
- Explosive strength and density
- Charge length
- Flyrock control
- Air blast limitations

However, if the blast area is well covered or when drilling through thick topsoil, appropriate stemming lengths need to be agreed with the Engineer.
A12.10.7.2 Ground vibration, air blast and fly rock monitoring

The lump sum tendered under this item shall include for providing and operating all equipment necessary to successfully monitor all blasting
operations and thereby the Contractor’s compliance with the specification. It shall include for all incidentals necessary to operate, process and
report results from the equipment.
a) Monitoring plan and pre-blasting baseline census and survey
Unless otherwise specified all blasts shall be monitored for ground vibrations, air-blast and by high speed video recording at/from
locations/monitoring stations to be agreed with the Engineer. The Contractor shall engage the services of an independent, suitably qualified and
experienced reputable specialist consultant(s), accepted by the Engineer to carry out the monitoring and record the requisite data. A minimum of
two monitoring stations will be required to be in operation for each and every blast.
The monitoring records of each blast shall show the date, time, weather conditions, location, the type and amount of explosive used, the maximum
mass of explosive charge detonated instantaneously and any other relevant data as may be required.
A monitoring plan, indicating the locations of measurement points shall be submitted to the Engineer for approval four weeks prior to the
commencement of blasting operations. Monitoring shall include a base-line measurements/census carried out, no more than 10 calendar days
prior to blasting indicating the condition of all potentially impacted infrastructure and structures, including cracks and crack widths prior to blasting
activities. Thereafter key points/most critical and sensitive structures identified from the census will be inspected immediately after the first two
blasts and reported upon and then again once blasting is completed.
Where blasting is conducted over an extended period, regular inspections and censuses, at least at monthly intervals, are required. The consultant
will be required to provide a fully documented and illustrated report within 2 weeks of conducting out an inspection.
Where complaints are received of damage caused by blasting, the Contractor shall immediately investigate such and submit a written report to
the Engineer on each complaint. If considered valid, the Engineer will instruct the Contractor to obtain a written report from the specialist consultant.
The Contractor shall not proceed with any further drilling and blasting on that section of the work until he has been advised accordingly.
In the event of the laid-down vibration parameters set out in Table A12.10.7-1 or those that may be subsequently agreed to following blasting trials
for the various sections of the works being exceeded or in the event of a valid recording not being made available as required by these
specifications, the Engineer reserves the right to ascertain by whatever means, whether damage was caused by the blast within its potential zone
of influence. All costs incurred in establishing such possible resultant damage and the repair thereof will be to the Contractor’s account.
b) Establish Site Specific Parameters
(i) Ground Vibrations
At the onset of the works and as part of the first blasting trials, the Contractor shall record the peak particle velocities (PPV) using
triaxial seismographs and over-pressure using approved industry standard equipment to establish the relationship between these
parameters and the distance from the blast and mass of explosives detonated instantaneously. The apparatus shall have the
capability of providing both continuous paper trace and digital/analogue records of the data required.
This monitoring and evaluation of the damage to the rock surfaces will be used by the Engineer to establish the total allowable
explosive charge to be detonated per delay and detonation patterns and sequences which the Contractor will not be allowed to exceed
for subsequent production blasting.
The guidelines for the maximum allowable Peak Particle Velocity (PPV) to prevent damage to structures given in Table A12.10.7-1
shall be adhered to for blasting trials. They will be assessed against results recorded and observed consequences and where
necessary the maximum PPV’s shall be reduced. The allowable maximum PPVs shall not be increased irrespective of the outcome
of observations during blasting trials.
Table A12.10.7-1: Guidelines for the Allowable Peak Particle Velocity to Prevent Damage (at 50Hz)
Structure under consideration Maximum PPV (mm/s)
Onset of fracturing of rock 250
National roads /Asphalt roads 150
Heavily reinforced concrete structures 120

Property owned by the concern performing blasting operations where minor plaster cracks are
84
acceptable
Strong masonry walls 50
Steel pipelines 50
Commercial property in reasonable repair 25
Concrete more than 10 days in age 20
Private property 10
Green Concrete i.e. less than 3 days old 5
Note: The onset of damage is a function of the frequency of the vibrations, namely the lower the frequency the lower the limit will be for the onset
of damage. The higher frequencies from the blast are first to be attenuated as the vibrations propagate from the source of the blast and are
therefore the lowest frequencies that propagate the furthest. The onset of damage is also dependant on the resonant frequency of the
structures/infrastructure under consideration. The limits presented in Table A12.10.8-2 are typically for the higher frequency limits, greater than
50 Hz. No more than 5 % of the results shall exceed these limits. The final thresholds for the various elements of the contract will be established
from the trial blasts.

At the onset of blasting trials, estimates of Peak Particle Velocity at any distance D in metres for the weight E in kg of explosive detonated
instantaneously may be made from Equation 1, namely:
D b
PPV = a( ) ………………………..(1)
√E
Where a and b are site specific constants.

Initial values of a = 1140 and b = -1.65 which are common practice in South Africa, shall be used for the initial trials until such time as site specific
constants are established.
(ii) Air blast
A guideline for the level of perception for various levels of blast pressure and allowable blast pressure is presented in Table A12.10.7-
2. These guidelines shall initially be adhered to for blasting trials. They will be assessed against results recorded and observed and
where adjudged necessary adjusted as required.
Table A12.10.7-2: Levels of Perception and Allowable Limits of Blast Pressure
Level of perception Blast Pressure (dB)
Readily acceptable – rattling of lose windows/doors/ceiling panels 110
No more than 10 % of measurements should exceed this value. 128
No measurements at any residential or sensitive structures should exceed this limit. 134
Less than 10% of blasts shall be allowed to produce an air blast pressure of more than 128dB at the closest identified sensitive location, and no
blast shall generate air blast pressures greater than 134dB.
At the onset of the blasting trials, estimates of air blast at any distance D in metres for the weight E in kg of explosive detonated instantaneously
may be made from Equation 2, namely:
D b
PPV = a−b log ( ) ………………………..(2)
√E
Where a and b are site specific constants. Log is log to base 10.
The initial values of a = 165 ±2 0 for confined blasts and a = 195 for unconfined blasts. The decay factor b ≈24. These values of a and b are
common practice in South Africa shall be used for initial trials until such time as the site-specific constants are established.
The Contractor shall monitor blast induced ground vibration and air blast levels for each blast. The Contractor shall have sufficient measuring
equipment (triaxial seismographs) permanently deployed on site, at the requisite strategic locations, for the duration of drilling and blasting
operations to record ground vibrations, air blast and fly rock for all blasts. The equipment shall be correctly set up to capture the full event without
exceeding respective sensitivity ranges. The Contractor shall confirm in writing that the equipment is fully operational and appropriately set up
24hrs before commencing to charge any blast and then again immediately prior to detonating the charge.
(iii) Fly Rock
The Contractor is required to establish a fly rock risk zone defining the area where fly rock may extend to. This zone shall be cleared
before each blast. As fly rock is conservatively considered to be a function of mean predicted blast fragment size and drill hole
diameter, fly rock risk zones need to be established for the various blast configurations from the trial blast. Mean predicted blast
fragment size is typically determined by way of the KuzrRam model of Cunningham as part of the blast design, see reference 1.
At the onset of blasting trials, minimum estimates of throw distance L which must be cleared, shall obtained from estimated the graphs
for throw distance L in metres for various mean fragment sizes and blast hole diameters presented in Fig 1 below.

A12.10.7.3 Process
a) Preparation
Prior to drilling, the Contractor shall commence by removing all overburden, rippable rock and loose material over the area to be excavated to
expose the rock requiring controlled blasting. This clearing will extend at least 5,0 m beyond the perimeter of the required blasting limits.
Thereafter, depending on the depth of excavation required, blasting will continue in a series of benches/lifts.
Once the slope is scaled of all loose rock and the required support is installed, it shall be cleared of all loose fist size rock and greater, whereafter
setting-out and drilling of the following bench may commence.
The Engineer’s approval of the clearing shall be obtained one day before the setting out of the holes.
b) Drilling
The Engineer’s approval of the setting out shall be obtained one day prior to drilling of any blast holes. Drilling accuracy, both to line and level, is
of prime importance, especially for controlled perimeter blasting. The Contractor shall take particular care to accurately set out sight lines and
guiderails to control alignment, inclination and depth of blast holes
Individual bench heights/lifts shall not exceed 10 m, or that dictated by the rock support requirements indicated in the Contract Documentation,
drawings or as determined by the Engineer, whichever is the lesser. The Contractor shall provide safe and appropriate access and opportunity
in his programme for subsequent necessary scaling, inspections and mapping by the Engineer and for the installation and testing of rock
reinforcement and support as may be needed.
Blast holes shall not be greater than 75 mm in diameter, unless the Contractor can conclusively convince the Engineer by demonstrating by way
of successful trial blasts, that a larger diameter is preferable.
Holes shall be accurately set out and collared to within 75 mm of the position indicated on the blast pattern design within the volume of rock that
requires to be excavated. No hole may be set out or collared behind the excavation line.
For controlled bulk blasting, cushion and buffer blasting blast holes should not deviate more than 2 %, once collared, from the plane of the planned
slope nor and the end of a hole in the plane of the slope should not, deviate more than 2 % of the height of the bench/lift, from the targeted
horizontal position. For controlled perimeter blast holes required tolerance of the deviation of the blast holes shall be 1 % as specified above.
The Contractor shall undertake and submit the results of a blast hole orientation survey to the Engineer for approval of all blasts one day prior to
planned charging of blast holes. No more than 5 % of the holes shall deviate from the specified tolerances.
Holes, which upon orientation measurement, deviate more than specified percentage (%) from the plane of the slope, or the ends of which deviate
more than the specified % of the height of the bench/lift, shall not be charged up, save that 5 % of these holes, provided that the deviation does
not exceed 2 % in the case of perimeter holes and 3 % in the case of bulk, cushion and buffer blasting, may be charged as agreed with the
Engineer. The remaining out of tolerance holes shall instead be fully filled with stemming and abandoned and a new hole drilled to replace it.
Holes which are over drilled by more than 100 mm of the required depth, shall be stemmed up to the required depth before charging takes place.
Holes for line drilling shall comply with the requirements for bulk blast drilling. Holes shall be strictly drilled at 300 mm centre to centre. Where
instructed or approved by the Engineer additional holes shall be drilled to create the desired final excavated surface with negligible damage.
Spacing of pre-split holes shall be such that the result is a uniform, clean, undamaged intact even fracture surface between holes. Any spacing
greater than 450 mm shall be subject to the Contractor being able to demonstrate to the Engineer that the required tolerances and a uniform
undamaged intact even surface is produced. Notwithstanding the above the maximum allowable hole spacing shall be 750 mm.
Pre-split holes shall extend to at least 200 mm, but not more than 500 mm, below the level of the bulk blast holes.
The line of pre-split holes shall extend beyond either end of the excavation for a distance not less than 10 m beyond the limit of controlled bulk
holes to be detonated, or to the end of the cutting as applicable.
The Contractor shall drill one or more rows of buffer holes with reduced charge and burden, adjacent to and inside the pre-split line in such a
manner as to avoid damage to the pre-split surface. The buffer holes may not be closer than 1,25 m from the presplit line of holes.
The Contractor shall adjust his drilling operations to compensate for drift of previous levels and for the offset at the start of new levels to maintain
the overall specified sloped plane shown on the drawings and cross sections.
c) Charging Up
Twenty four hours prior to charging up or blasting each and every blast, the Contractor shall demonstrate to the Engineer during a joint inspection
that all vibration and over pressure monitoring equipment is in place and that the equipment is in 100 % in working order. The Contractor shall
provide the Engineer with written confirmation of the foregoing.
The explosive charge of a pre-split or smooth blast shall be decoupled from the wall of the blast hole and the air space between explosive charge
and the hole, as may have be established from blasting trials and approved by the Engineer, shall remain open.
The bottom charge of a pre-split or smooth blast hole may be larger than the line charges above it but shall not be large enough to cause damage
or excessive back-break of the remaining rock face. The top charge of the pre-split and smooth blast holes shall be placed far enough below the
collar to avoid over-breaking and cratering the surface.
All charges shall be accurately made up and inserted into the holes at the correct spacing, and all holes shall be correctly stemmed and linked in
the correct sequence with detonators being correctly delayed to ensure the required sequence and timing of detonation and to eliminate the
possibility of live charges remaining after detonation.
d) Sequence of Detonation
(i) Pre-splitting
Dependant on the outcome of the trial blasts, and/or the project requirements, the Contractor may either detonate the pre-split holes:
- Simultaneously, prior to and well in advance of the controlled bulk drilling and blasting which may be done several weeks of months
later, or
- Simultaneously, but at least 50 milli-seconds ahead, or such time interval as established from the trial blasts, of the first row of bulk
blast holes.

- These holes are detonated simultaneously, prior to the main bulk blast
(ii) Smooth blasting
The row of smooth blast holes is detonated last, after the bulk blast, at least 50 milli-seconds, or such time interval as established
from the trial blasts, after the row of buffer holes nearest to the smooth blast line is fired.
(iii) Controlled bulk blast
Controlled bulk blasting entails sequentially detonating single rows of blast holes, or portions thereof, starting with the row closest to
the free face farthest away from the line of pre-split or smooth blast holes. The sequence of detonation of the rows, or portions of rows
must progress in steps, using adequate delay intervals to limit the mass of explosive detonated simultaneously so as to keep ground
vibrations to safe limits established for the contract by blast trials.
e) Variation in Conditions
The Contractor shall immediately notify the Engineer of changed conditions. All drilling and blasting work shall immediately stop. Prior to
commencing with or carrying out any further drilling and blasting, the Contractor obtain the Engineer’s approval to proceed with one of the prior
approved blasting patterns as determined from the trial blasts.
Should it come to the Engineer’s attention that conditions have changed he will instruct the Contractor to halt all work immediately and to investigate
such. The Contractor shall obtain the Engineer’s approval of which prior approved drilling and blasting pattern he intends changing to prior to
proceeding with any further excavation.
Should conditions be encountered during execution of the works for which no trial blasts were undertaken, the Contractor shall undertake further
trials as agreed with the Engineer before continuing with further productive drilling and blasting on that section of the works.
f) Post blast requirements
On completion of a blast, the blast created surface/slope shall be scaled and made safe. All blasted material shall be removed along the entire
length of the blast and shall be inspected and approved by the Engineer prior to further trial/production drilling and blasting.
The Engineer’s approval of the preparation, setting out as well as the subsequent installation, testing and proving compliance of any rock support
required shall be obtained before any further drilling and blasting pertaining to the next bench of the section of the site under consideration
commences.
When completed, the excavated surface (face) of the cutting shall conform to alignment, inclinations and tolerances as shown on the drawings or
as might be directed by the Engineer in writing during the execution of the works. The excavated profile shall be checked for line, level and under-
break using methods agreed with and approved by the Engineer. Rock protruding more than the allowable tolerance within the payment line shall
be removed with mechanical breakers, or other approved non-detonating explosives.
Should the Contractor excavate to dimensions in excess of those specified or instructed by the Engineer, whether to remove damaged material
or for reasons of safety or for his own convenience, he shall at his own expense and when required by the Engineer, fill in the excess excavation
with concrete or shotcrete of approved quality or with other material approved by the Engineer, or carry out additional trimming to the satisfaction
of the Engineer.
All work required and possible delays which result from the Contractor having to remove underbreak as well as having to re-install rock support
damaged when removing underbreak, shall be carried out without additional payment or extension of time.
g) Records
Without in any way relieving the Contractor and his personnel of their responsibilities in terms of the Explosives Act No.26 of 1956, or any
subsequently promulgated relative legislation, the Contractor shall survey and record the actual location of every hole loaded, the charge and
timing of every hole, as well as the intended drilling pattern, loading and type of charge in each blast for submission to the Engineer and shall
allow the Engineer access to all records maintained for the Inspector of Explosives or Government Mining Engineer as the case may be.
Within 24 hours after every blast the Contractor shall provide the following information to the Engineer:
- Details of the actual total mass of explosives used,
- The approximate volume of material loosened or area pre-split/smooth blasted,
- The maximum simultaneous mass of explosives detonated within the delay intervals, and
- Blast vibration and over pressure and other monitoring results (including video/s of flyrock).
Should the Contractor fail to submit this information as required, the Engineer may instruct that no further drilling or blasting be undertaken until
such time as the required information has been received. Any ensuing delay or disruption to the Contractor’s programme will be for his own
account.
The supply of any information to the Engineer in respect of controlled blasting techniques does not relieve the Contractor of his responsibilities
under the Contract.
h) Use of non-detonating explosives
Blasting shall not be carried out within 10 m of any works, infrastructure or structure, unless otherwise agreed to in writing by the Engineer.
Furthermore, whenever, in the opinion of the Engineer, there is careless or inappropriate use of explosives or where the Engineer considers that
further blasting might damage the rock, use of detonating explosives shall be discontinued. In the event of the foregoing the excavation shall be
undertaken/completed by either one of the following, namely, propellants, swelling agents, hydraulic wedging or mechanical breakers. In these
circumstances, and unless the said conditions and quality of the rock could not have been foreseen, the Contractor shall not be entitled to any
additional compensation or extension of time and he shall be reimbursed at the rates tendered for the work as though it had been undertaken by
means of detonating explosives.
i) Restrictions
In addition to the normal statutory restrictions and regulations, blasting shall not be permitted:
- When there is low dense cloud cover of more than 50 %
- When the wind velocity is greater than 10 km/h towards the area of concern
- Before 09h00 and after 16h00
- On Sundays and public holidays
- Unless timeous notifications have been issued to the appropriate parties as per Clause A12.10.3.4.

A12.10.8.1 Adequacy of the results
If at any time The Engineer finds that the methods of drilling and controlled blasting employed do not, in his opinion, produce desired the results
of a uniform slope and clean fractured surface without overbreak and with minimal blast damage, all within the tolerances specified; or result in
excessive ground vibrations and damage, he may issue a written instruction to the Contractor to immediately suspend all drilling and blasting
Following this, the Contractor shall investigate and submit a written report on the cause of the alleged inadequate results and/or damage and
submit a revised drilling and blasting pattern for approval by the Engineer.
In this instance the Engineer may order that further successful blasting trials be undertaken before full production may continue with the revised
pattern.
Should a disagreement between the Engineer and the Contractor arise and the Contractor contends that a given result rejected by the Engineer
cannot be improved upon, the Contractor has recourse to Clause A12.10.7.1c) and can call for the opinion by an agreed independent blast
specialist and proceed accordingly.

B12.10 HARD EXCAVATION BY BLASTING
CONTENTS
B12.10.1 SCOPE
B12.10.2 DEFINITIONS
B12.10.3 GENERAL
B12.10.5 MATERIALS
B12.10.8 WORKMANSHIP
B12.10.1 SCOPE
B12.10.3 GENERAL

B12.10.5 MATERIALS



C12.10 HARD EXCAVATION BY BLASTING
(i) Preamble
2.
pay items.
1,0 km.
C12.10.1 Excavation in hard rock using controlled blasting techniques cubic metre (m3)
The unit of measurement shall be the cubic metre of rock excavated employing controlled blasting techniques in cuts, borrow pits and quarries.
The volume measured for payment shall be shall be the volume of the compacted earthworks or layerworks calculated using the authorised
dimensions for those works given in the Contract Documentation. The tendered rate shall include
-
all costs in employing controlled drilling and blasting techniques in hard rock limiting the mass of explosive to be detonated simultaneously
to ensure that the required and specified limits of PPV are not exceeded and ensuring that all other conditions and constraints as specified
are satisfied.
- for any additional drilling, setting out, setting-up drilling equipment, special techniques, explosives or special explosives and any other
incidentals necessary to complete the blasting without any fly-rock and with minimal possible damage to the remaining rock.
- all additional costs and disruption to the Contractor’s programme resulting from carrying out the required trial blasts and test sections.
No separate payment will be made for cushion blasting. The cost of using cushion blasting techniques shall be included in the rates for excavation.
No separate payment shall be made for oversize material excavated to spoil.

C12.10.2 Pre-splitting - base rate for holes @ 750 mm c/c square metre (m2)
The unit of measurement shall be the square metre of net fracture surface created that is measured on the payment cut slope line. Measurement
will only be made for pre-splitting carried out in accordance with approved pre-splitting specified in the Contract Documentation and drawings, or
as ordered in writing by the Engineer. The base rate covers all the activities and requirements specified below, for creating a pre-spilt, with holes
strictly drilled at 750 mm centre to centre.
The base rate tendered shall include for pre-splitting blasting trials, for drilling and charging the holes, any additional works such as but not limited
to moving all plant and equipment to the respective drilling site and moving between holes, setting-up drilling equipment, any additional setting
out and control measures, limited spacing and diameters of pre-split holes, any additional explosives and any other incidentals necessary to
complete the pre-splitting work as specified.
C12.10.3 Pre-splitting - compensation for additional holes metre of hole (m)
The unit of measurement shall be the metre length of pre-split hole drilled and charged over and above the total length required for the base case,
where charged holes are spaced at 750 mm c/c. Only those additional holes as instructed and approved by the Engineer in writing prior to blasting
will be paid for.
The rate tendered shall include for drilling and charging the additional holes, for moving all plant and equipment to the drill site and moving between
holes, for setting-up drilling equipment, any additional setting out and control measures, limited spacing and diameters of drilled holes, and any
other incidentals necessary to complete the additional drilling work as required.
C12.10.4 Smooth blasting - base rate for holes @ 1500 mm c/c square metre (m2)
The unit of measurement shall be the square metre of net fracture surface created that is measured on the payment cut slope line. Measurement
will only be made for work carried out in accordance with approved smooth blasting techniques specified in the Contract Documentation and
drawings, or as ordered in writing by the Engineer. The base rate includes all the activities and requirements specified below, for creating a smooth
blast, with holes strictly drilled at 1500 mm centre to centre.
The base rate tendered shall include for all smooth blasting trials, for drilling and charging the holes, any additional works such as but not limited
to moving all plant and equipment to the respective drilling site and moving between holes, setting-up drilling equipment any additional setting out
and control measures, limited spacing and diameters of smooth blast holes, any additional explosives and any other incidentals necessary to
complete the smooth blasting work as specified.
C12.10.5 Smooth Blasting - compensation for additional holes metre (m)
The unit of measurement shall be the metre length of smooth blast hole drilled and charged over and above the total length required for the base
case, where charged holes are spaced at 1500 mm c/c. Only those additional holes as instructed and approved by the Engineer in writing prior to
blasting will be paid for.
The rate tendered shall include for drilling and charging the additional holes, for moving all plant and equipment to the drill site and moving between
holes, for setting-up drilling equipment, any additional setting out and control measures, limited spacing and diameters of drilled holes, and any
other incidentals necessary to complete the additional drilling work as required.
C12.10.6 Line Drilling - base rate for holes @ 300 mm c/c square metre (m2)
The unit of measurement shall be the square metre of net cut slope that is measured on the payment cut slope line. Measurement will only be
made for line drilling carried out in accordance with approved line drilling specified in the Contract Documentation and drawings, or as ordered in
writing by the Engineer. The base rate includes for all the activities and requirements specified below, for creating a drill, with holes strictly drilled
at 300 mm centre to centre.
The rate tendered shall include for all line drilling trials, any additional works of moving all plant and equipment to the drilling site and between
holes, any additional works of setting-up drilling equipment, any additional setting out and control measures, limited spacing and diameters of line
drilled holes, and any other incidentals necessary to complete line drilling work as specified.
C12.10.7 Line Drilling – compensation for additional holes metre (m)
The unit of measurement shall be the metre length of uncharged hole drilled over and above the total length of uncharged holes required for the
base case, where uncharged drill holes are spaced at 300 mm c/c. Only those additional holes as instructed and approved by the Engineer in
writing prior to blasting will be paid for.
The rate tendered shall include for drilling the additional holes, for moving all plant and equipment to the drill site and moving between holes, for
setting-up drilling equipment, any additional setting out and control measures, limited spacing and diameters of drilled holes, and any other
incidentals necessary to complete the additional drilling work as required.

D12.10 HARD EXCAVATION BY BLASTING
CONTENTS
D12.10.1 SCOPE
D12.10.2 GENERAL
D12.10.1 SCOPE
D12.10.2 GENERAL
The Contractor shall submit comprehensive product data, specification, performance data and compliance certificates certified by the manufacturer
and relevant testing authority as might apply for all explosives, detonators and initiation systems within 28 days of entering into the contract with
the Employer.









12.11 GEOSYNTHETICS
CONTENTS
A12.11.1 SCOPE
A12.11.3 GENERAL
A12.11.5 MATERIALS

A12.11 GEOSYNTHETICS
A12.11.1 SCOPE
This Section details only material specifications and uses of geosynthetics including their application as barriers, containment, drainage
(transmission), filtration, protection, reinforcement, separation, erosion control or as frictional interlayer systems. This Section does not contain
any Measurement and Payment items.
Geosynthetic Materials - collective term for geogrids, geotextiles and geocells made from a synthetic or natural polymer, in the form of a sheet,
a strip or a three-dimensional structure, used in contact with soil and/or other materials in geotechnical and civil engineering applications
Geotextiles - are planar soil and polymeric (synthetic or natural) textile material, which may be nonwoven, knitted, woven knitted or
stitch-bonded fibres or yarns, used in contact with /or other materials in geotechnical and civil engineering applications.
Geogrids - are planar, polymeric structures consisting of a regular open network of integrally connected, tensile elements, which may be linked
by extrusion, bonding or interlacing, whose openings are larger than the constituents.
Geonets - are a geosynthetic consisting of parallel sets of ribs overlying and integrally connected with similar sets at various angles.
Geomembranes - are continuous flexible sheets or rolls manufactured from one or more synthetic materials. They are relatively impermeable
and are used as liners for fluid or gas containment and as vapour barriers.
Geocomposites - are geosynthetics made from a combination of two or more geosynthetic types. Examples include geotextile-geonet;
geotextile-geogrid; geonet- geomembrane; or a geosynthetic clay liner (GCL). Prefabricated geocomposite drains or prefabricated vertical drains
(PVDs) are formed by a plastic drainage core surrounded by a geotextile filter.
Geosynthetic clay liners (GCLs) - are geocomposites, prefabricated with a bentonite clay layer typically incorporated between a top and
bottom geotextile layer or geotextile bonded to a geomembrane or single layer of geotextile. Geotextile-encased GCLs are often stitched or
needle- punched through the bentonite core to increase internal shear resistance. When hydrated, they are effective as a barrier for liquid or
gas and are commonly used in landfill liner applications often in conjunction with a geomembrane.
Geopipes - are perforated, slotted or solid-wall polymeric pipes used for drainage of liquids or gas (including leachate or gas collection in landfill
applications). In some cases the perforated or slotted pipe is wrapped with a geotextile filter.
Geocells - are three-dimensional, permeable, polymeric (synthetic or natural) honeycomb or similar cellular structure, made of linked strips of
geosynthetics. Strips are joined together to form interconnected cells that are in-filled with soil and sometimes concrete. In some cases 0,5 to
1,0 m wide strips of polyolefin geogrids are linked together with vertical polymeric rods used to form deep geocell layers called geomattresses.
Geofoam - blocks or slabs are created by expansion of polystyrene foam to form a low-density network of closed, gas-filled cells. Geofoam is
used for thermal insulation, as a lightweight fill or as a compressible vertical layer to reduce earth pressures against rigid walls.
Geosynthetic Cementitious Composite Mats (GCCMs) - is a flexible, concrete impregnated fabric that hardens on hydration to form a thin,
durable waterproof and fire resistant concrete layer. It is used in concrete channel lining, slope protection, bund lining, remediation of existing
concrete structures and culvert lining.

A12.11.3 GENERAL
All materials used in the works shall meet the appropriate standards given below and/or specified in the Contract Documentation and shall be
subject to the approval of the Engineer. The Contractor shall submit product certificates, conformance documentation (as per Part D) related to
the specifications, test results as required together with samples of materials and, where applicable, designs that he proposes to use in the
construction of the works to the Engineer for his acceptance/approval as provided for in the Contract Documentation.
A12.11.3.1 Uses of geosynthetics

Geosynthetics may be used for a variety of tasks in geotechnical applications including:
a) Barrier
As a barrier to prevent migration of liquids or gases.
b) Containment
To contain soil or sediments to a specific geometry and prevent their loss. The contained fill takes the shape of the inflated at-rest geometry of
the geosynthetic container.
c) Drainage (also known as transmission)
To collect and transport fluids
d) Filtration
To allow passage of fluids from a soil while preventing the uncontrolled passage of soil particles.
e) Protection
As a localised stress reduction layer, to prevent or reduce damage to a given surface or layer.
f) Reinforcement
To resist stresses or contain deformations in geotechnical structures.
g) Separation
To provide separation between two dissimilar geotechnical materials, to prevent intermixing.
h) Surficial erosion control
To prevent surface erosion of soil particles due to surface water run-off and/or wind forces.
i) Frictional interlayer
As a friction interlayer to increase or reduce friction across the interface.

A12.11.5 MATERIALS
A12.11.5.1 General
The Contractor shall, within 28 days of entering into the contract with the Employer, provide conformance documentation obtained from his supplier
confirming the compliance with the specified properties before establishing such materials on site. Where so specified samples of the materials
shall be tested by an approved testing facility to ensure compliance with the specified requirements employing the appropriate test methods. Such
shall include geotextile qualities regarding soil retention; permeability; clogging; durability, strength and any other specified performance criteria.
A12.11.5.2 Storage and Handling

Geotextiles shall be stored under suitable cover according to the manufacturers recommendations and shall not unnecessarily be exposed to
direct sunlight as they are susceptible to UV damage. Geotextiles shall be protected from mechanical damage during delivery and during
construction.
A12.11.5.3 Durability
Geotextile shall comply with the following durability specifications:
a) Resistance to chemical attack

The geotextile shall withstand the level of aggressiveness of the soil and ground water given below without significant loss of its strength and
hydraulic properties during its design life of 25 years:
The geotextile shall withstand soil and ground water with a pH in the range of 4 to 9 (pH to be determined by SANS 10224, SANS 3001).
The geotextile shall withstand soil (as paste) and ground water containing salts with a conductivity of up to 1,0S/m (conductivity to be determined
by SANS 10224, SANS 3001).

b) Resistance to ultra-violet light
The geotextile shall maintain at least 80 % of its original value when exposed to sunlight for 1 500 hours. as determined under ASTM D45355 or
ASTM D7238 and EN ISO 12224
c) Resistance to rot
The geotextile shall be manufactured of an entirely rot-proof polymer.


To ensure quality of materials testing may be specified to verify compliance with the specified requirements. This includes geotextile qualities
regarding soil retention; permeability; clogging; durability and strength. Table A12.11.8-1 details various test methods that may be used to verify
compliance with specified properties.
Table A12.11.8-1: Generic specification tests
Property Test method Comment
ASTM D5261/ISO 9864

Mass/unit area
SANS 9864
ASTM D5199
Thickness SANS 9863-1
ISO 9863-1
Stiffness ASTM D1388
ASTM D4632 There are a number of variations:
Tensile Strength SANS 1525 ASTM D1682, D451, D4595
ISO 10319 & ISO 10319
Seam strength ASTM D4884
Fatigue strength No accepted standards
Burst strength ASTM D3786
Grab Tensile Strength ASTM D4632
ASTM D4533
Tear strength Trapezoidal tear test
Puncture tests
- Static Puncture Strength CBR - ASTM D4833

ISO12236 CBR Plunger used in ISO/DIS 12236
SANS 12236 and DIN 54307 in Germany
- Puncture Resistance ASTM ISO 13433

SANS 13433
Friction behaviour ASTM D5321
ASTM 5262
Tensile creep ISO 13431
SANS 13431
Degradation ASTM D5819
ASTM D5567 - 94(2011): Standard Test Method
Hydraulic properties
for Hydraulic Conductivity Ratio (HCR) Testing of
Porosity ASTM D4751(AOS)
Soil/Geotextile Systems
Pore size SANS 12956
or
ASTM D5101 - 12: Standard Test Method for
Percent open area ISO 12956
Measuring the Filtration Compatibility of Soil-
Equivalent opening size CW-02251/D4751
Geotextile Systems
ASTM D4491
Permittivity
ISO 11058
Cross plane permeability
SANS 11058
Permittivity under load ASTM D5493
Permittivity ASTM D4716
In-plane permeability ISO 12958
Soil retention
ASTM D5141
Above ground silt fences
Endurance ISO 13437
ASTM D1175
Abrasion
ASTM D4886
ISO 13427
ASTM D4355 as described in

ASTM G26
ASTM G53 Ultra- violet fluorescent light test
Ultraviolet degradation
ASTM D1435 Plastics weathering
ASTM D5970
ASTM D7238
ASTM D1388
Temperature degradation For cold weather applications
ASTM D746
ASTM D543
Chemical degradation ASTM D5322 For landfill sites
ASTM D5496 Field incubation procedure
Biological degradation Unlikely due to high molecular mass

B12.11 GEOSYNTHETICS
CONTENTS
B12.11.1 SCOPE
B12.11.3 GENERAL
B12.11.5 MATERIALS
B12.11.1 SCOPE
B12.11.3 GENERAL

B12.11.5 MATERIALS



C12.11 GEOSYNTHETICS
Measurement and Payment will be covered under the Chapters where applicable.

D12.11 GEOSYNTHETICS

CONTENTS
D12.11.1 SCOPE
D12.11.2 GENERAL
D12.11.1 SCOPE
D12.11.2 GENERAL









12.12 CONSTRUCTION DEWATERING
CONTENTS
A12.12.1 SCOPE
A12.12.3 GENERAL
A12.12.5 MATERIALS
A 12.12.8 WORKMANSHIP

A12.12 CONSTRUCTION DEWATERING

A12.12.1 SCOPE
This Section covers various methods of construction dewatering of excavations including sump pumping, well points, water jet eductors and
shallow/suction wells necessary to lower and control groundwater levels and hydrostatic pressure to permit excavation and construction to be
performed. The responsibility for planning and conducting dewatering operations in accordance with best practice, the requirements of these
specifications or as instructed by the Engineer, rests solely with the Contractor.
Sump pumping - is the simplest method of dewatering excavations and is usually undertaken within the excavation. A sump is created by
excavating a hole which may either be left open unlined, open but supported by boarding and/or backfilled partially or wholly with a suitably graded
filter material. It is most effective in clean gravels and coarse sands and is generally unsuitable in materials containing a lot of fines because of
the danger of internal erosion and loss of fines unless special measures are taken.
Pumping may either be by way of sludge/submersible pumps placed in the sump or by way of a suction hose connected to a discharge pump
placed remotely at a convenient place in the dry.
Sumps are usually sited along the inner perimeter of excavations, below the invert level, and made big enough to hold sufficient water to match
the pumping capacity to keeping the excavation floor drained for the duration of the construction. A pump is provided for each sump and connected
to a discharge pipe, which conveys and disposes the pumped ground water to an approved destination.
Well point systems - are small well screens about 50 mm diameter, between 0,5 m to 1,0 m long, connected to the bottom of a small diameter
riser pipe which is usually water jetted down into the water bearing stratum with a lance to the required depth, generally not deeper than about
7,0 m. They are typically used in sandy gravels, sands and down to fine sand. With additional measures and augmentation they can also be
used to drain fine silty sands.
Well points are installed as a series of small wells along the perimeter of an excavation and are each connected directly through the riser pipe to
a common header pipe from which the water is pumped by a vacuum assisted centrifugal pump to an approved discharge point. The connection
between the riser pipe and common header pipe may either be directly, or more commonly by a short flexible pipe also referred as a swing joint.
Each connection between the riser pipe and header is fitted with a gate valve.
The effective depth of drawdown is limited to between 5,0 m to 6,0 m depending on the permeability and soil structure. Air-leaks/efficiency of the
system lines and connections may result in further reducing the depth of drawdown. Multistage systems are necessary for greater drawdown
depths.
Water jet eductor well systems - are similar to well point systems except that the riser pipe consists of a two part configuration, namely a
supply/feeder line and return line. Ground water is sucked through a well screen, into an eductor fitted to the base of the feeder pipe by a vacuum
formed when a high pressure jet of water fed from a surface high pressure ring main is forced through the venturi within it. The jetting water
together with the groundwater is then forced up through the return line of the riser pipe, to the return header ring main and discharges into a
collector/settling/holding tank. Part of the return water is drawn off and re-used by the supply water header pump to feed the high pressure ring
main, whilst the balance overflows and is discharged to waste. Typically, the input flow is about 1,5 to 2,5 times the induced flow, resulting in a
very low efficiency and slow extraction rates.

The main advantage of the water jet eductor system is that the depth of dewatering achievable is not restricted by the limitation of attainable
suction pressures and deep single stage dewatering from surface is possible. They are therefore ideally suited for dewatering silty sands and
sandy silts and/or where space is lacking and multistage well pointing cannot be used.
Shallow/Suction wells systems - are shallow bored wells, each fitted with a riser pipe either coupled directly to a suction pump, or to a header
main which services a series of wells. This system works in the same way as a well point system with the difference being the well point is
replaced with a conventional well screen to ensure adequate filtering and with a larger diameter well which increases the radius of influence and
drawdown. Suction wells are well suited for high permeability soils, or in instances where jetting and lancing may be impeded by difficult ground
conditions or in water bearing rock and/or boulder formations which require boring.
Suctions wells may be required for sites which require pumping for an extended period and potential loss of fines is a concern, or on congested
sites, as a smaller number of riser pipes are required which may otherwise hinder construction activities.
Multistage dewatering - is undertaken for deep excavations whereby the dewatering and excavation is done progressively in depth stages of
about 5,0 m to 6,0 m, being the maximum suction head that can practically be achieved. Dewatering of the initial stage is first achieved to allow
the initial stage of excavation to be undertaken. Hereafter a second ring or line of wells is then sunk along the perimeter base of the excavation to
undertake the second stage of dewatering to a further depth. Once dewatering of the second stage is achieved the second excavation stage may
be undertaken. This sequence can be repeated until the required depth of dewatering is achieved. Multistage dewatering would also require
intermediate sumps and pumps at each stage to be lift the extracted water out to ground surface for further discharge to an approved disposal
site.
Ground water lowering monitoring point - may either consist of a stable open excavation for shallow monitoring, or an observation well for
monitoring to greater depth, both with the requisite reference datum from which levels can be recorded.
Ground water monitoring well - in its simplest form is no more than a slotted conduit, of minimum 25 mm internal diameter, which has either
been jetted in or placed in a predrilled hole to the required depth and provided with a lockable cap.
A12.12.3 GENERAL
A12.12.3.1 General
Groundwater conditions and/ or construction requirements may necessitate the design and application of site specific dewatering system/s to
ensure that safety is not compromised or the integrity of the founding and surrounding materials is not adversely affected by poor methodology or
equipment failure. Dewatering shall be conducted in such a manner to ensure that within the potential zone of influence of the dewatering activities,
no unacceptable ground subsidence, damage to any property, structures or facilities will occur and that it does not pose a threat to the public
health or create any hazard.
This may require that construction dewatering be undertaken by a specialist Contractor or sub-Contractor. The Contractor shall design the
dewatering strategy and layout plan(s). The supply, install, and operate all pumps, pipes, appliances, and equipment of sufficient capability to
maintain the requisite minimum lowered groundwater levels for all excavations requiring dewatering until they are backfilled to the required
specification.
The groundwater level shall normally be lowered and maintained at an absolute minimum of 1,0 m below the lowest excavation invert level, or to
such levels as may be specified in the Contract Documentation or instructed in writing by the Engineer.
The scope of the works shall also encompass the requirements of Clause A2.1.3.2 of Chapter 2.
Where necessary diversion ditches and dikes/earthen bunds shall be used, to prevent surface water from entering any excavation(s).
Unless specifically reflected in the pricing schedule, or where provision for such has been made in the Contract Documentation, the requirements
stipulated shall be deemed to be included in the rates for the works.

such as construction methodology, key equipment, materials, personnel as well as any programme constraints of the envisaged construction
process.
These method statements shall be prepared and submitted to the Engineer prior to commencement of that activity, within time scales
to avoid any delays in the commencement, continuation and completion of the required works. The Contractor shall, however, remain responsible
for all work-methods, materials, plant and equipment used, notwithstanding acceptance by the Engineer.
Once accepted in writing by the Engineer, these shall become the method statements in accordance whereby the relevant portion of the works

All materials used in the works described hereunder shall be fit for purpose.
Where specific dewatering works are specified in the Contract Documentation and for which provision is made for payment, such materials shall
meet the appropriate standards given below and/or specified in the Contract Documentation and shall be subject to the approval of the Engineer.
The Contractor shall submit product certificates, conformance documentation (as per Part D) related to the specifications, test results as required
together with samples of materials and where applicable, materials designs that he proposes to use in the construction of the works to the Engineer
for his acceptance/approval as provided for in the Contract Documentation.
The Contractor’s attention is drawn to the approvals required as indicated in Table A12.12.3-2 below regarding works carried out as per specified
design.

Table A12.12.3-1: Notifications/Approvals for specified and measured works
Clause Engineer’s Approvals Required for: Notice Period
Method Statements
A12.12.7.1a) Method statements for dewatering each work area. 2 weeks prior to construction
Construction Materials, Plant
Information on the materials for the main components of

A12.12.5 1 weeks prior to procurement
dewatering system(s)
Process
Prior to commencement of
Permits and wayleaves to dispose of removed water where
A12.12.7.1c) dewatering
required
A12.12.7.1b) Trial drain sections Prior to commencement of works
System fully operational and groundwater lowered to required Prior to commencement of

A12.12.7.2a)
levels excavations
Contractor to assess safety of
A12.12.7.2b) Dewatering system fails or is suspended works, Engineer may halt
excavation

The Contractor shall be solely responsibility for the design, installation, operation, monitoring, and removal of the dewatering system to comply
with the requirements of the specifications and all applicable statutory requirements.
The dewatering system shall be designed, installed and maintained to lower and control the groundwater elevations as specified in the Contract
Documentation to permit excavation, construction of structures, and placement of fill materials to be performed under stable dry
workable/trafficable conditions. The system shall be designed to prevent pumping fines from below grade or disturbing materials at and within the
proximity of the excavation invert. Wells shall be cased, and filter(s) shall be provided to prevent the pumping of fines.
Fluctuations of the groundwater level can occur due to seasonal variations in the amount of rainfall, runoff, and other factors not evident at the
time the site investigations borings were undertaken. The Contractor shall independently interpret the geotechnical and groundwater conditions
taking into consideration his proposed method(s) of construction. The Contractor shall perform additional exploration at his own expense as
necessary for the requisite design of the dewatering system.
Variations of ground conditions and groundwater levels between soil boring/sampling locations may occur. The Contractor shall take cognizance
of this and shall make reasonable allowance and incorporate the requisite flexibility in his planning and design of the dewatering system to
accommodate such potential variations. The Contractor shall install additional dewatering points and equipment as may be required throughout
the duration of the project to maintain groundwater level as specified, or as directed by the Engineer in writing.
The following information and assessments are ideally required for the design:
• Pertinent geotechnical and geo-hydrological data as might be obtained from, field inspections, sub-surface investigations and laboratory test
results. These would include:
- Ground profile descriptions.
- Results of geotechnical testing undertaken including soil grading, permeability and strength.
- In-situ testing including Standard Penetration Test, Dynamic Cone Penetration, Falling or Constant Head Permeability Tests and
Pump Tests.
- Static groundwater levels as recorded in trail holes, soil borings and test wells.
- Tidal and seasonal fluctuations of static ground water levels as might be available from monitoring piezometers installed in trails
holes, soil borings and test wells.
• Topographical Survey data/digital terrain models and cadastral boundaries, including potential ground water source zones such as drainage
ditches, rivers and streams.
• The location of all structures, services and infrastructure which could be potentially impacted by the construction dewatering activities.
All or some of the information listed above may be available and presented in the Contract Documentation, failing which it will be the Contractor’s
responsibility to obtain the further requisite minimum information he considers necessary.
A12.12.5 MATERIALS
Where so specified the Contractor shall submit samples and the requisite technical details and specifications of all the main components of the
dewatering system proposed, for acceptance by the Engineer, at least 2 weeks before the approved programmed trial/construction activity. Where
appropriate a prototype of the proposed system shall be assembled and presented to the Engineer for inspection.

A12.12.6.1 Requirements/Capability
Equipment used for dewatering shall be capable of jetting/drilling/advancing holes and wells of the required diameter for the proposed installations
to the required depths in the indicated materials, including provision for filter sand between the riser pipes and the in-situ material. Where so
specified the Contractor shall also be equipped to undertake pre-drilling of holes, possibly with temporary casings in intermediate and/or boulder
formations.
Should the type of apparatus, rig and/or equipment prove inappropriate for the requirements or conditions on site, these shall be replaced by
suitable equipment at the Contractor’s cost. The drill rig/equipment shall be able to complete all drilling operations, without loss of direction or
inclination, in all materials.
A12.12.6.2 Maintenance
All equipment shall be inspected, serviced and calibrated at regular requisite intervals and tested to ensure system functionality, efficiency and
accuracy.
At the commencement of the work the Contractor shall supply the Engineer, for all key plant to be used, the requisite maintenance plans and
schedules as required by the manufacturer, to keep them in the requisite working order. The Contractor shall for the duration of the contract,
submit monthly returns summarising all maintenance and repair work undertaken on the key equipment.
The Engineer may suspend the further use of the item of equipment plant in question if such is shown to be unsafe or ineffective. In this event the
Contractor shall replace that equipment to ensure that there is no interruption to any active dewatering programme.
The Contractor shall have fully functional and operational standby pumps with all accessories on site to cope with at least two simultaneous and/or
two successive breakdowns. The Contractor shall be so equipped and staffed so as to install and commission the requisite standby equipment
within 3hrs from the breakdown.
A12.12.6.3 Flow meters

Where the installation of flow meters is specified, these shall be calibrated at the commencement of each installation and shall record the volume
of ground water extracted to an accuracy of at least 5 litres (5ℓ). Flow meters shall be installed at the requisite locations. The frequency shall be
as agreed with the Engineer. The average daily extracted volume for each installation shall be recorded and submitted to the Engineer on a daily
basis.
A12.12.6.4 Noise suppression

Pumps may either be driven by diesel or electric motors. Within and adjacent to residential areas and other areas as required by the Engineer,
engines driving dewatering pumps, or any generators used to produce power to drive the motors, shall be equipped with residential type mufflers
and the noise levels shall not exceed 55 decibels at a distance of 15 m from the respective motor or generator.

A12.12.7.1 General
a) Method statement / Dewatering plan
Where so specified, the Contractor shall submit a detailed method statement/dewatering plan for indicated location/s, including the trial positions
at least two weeks prior to the programmed commencement date of dewatering. This shall include layout drawings and any shop drawings, design
calculations and assumptions including the following elements as may be appropriate:
- The proposed type of dewatering system.
- Arrangement, location, and depths of system components to meet the draw-down depth specified.
- Complete description of equipment and instrumentation to be used, with installation, operation and maintenance procedures.
- Types and sizes of filters.
- All requisite design calculations.
- Method of disposal of pumped water including designated disposal sites and requisite permits to dispose at these sites.
- Method and frequency of sampling and water quality monitoring.
- Type of filtration and chemical treatment of contaminated water, as applicable.
- Method for establishing and monitoring construction site groundwater levels as specified.
- Criteria for determining the acceptability of removing the dewatering system from operation.
- Contingency plans for dealing with settlement sensitive structures which may potentially be influenced by dewatering.
b) Trials for well system installations
Where so specified, the Contractor shall conduct a trial for every typical subsurface profile to be dewatered to demonstrate the suitability of the
installation method proposed, the efficiency of the pumping system and discharge rates achievable, that no fines are removed during pumping
and what the radius of influence/cone of depression resulting from pumping will be. The trial shall comprise of a single row of wells some 9,0 m
to 12 m long. Three observation wells shall be installed for each test section and pumping will continue until steady conditions are achieved.
Adjustment to the method and installation and/ or equipment used may be made to the proposed installation to obtain the desired or best possible
result. Following the outcome of the successful trial the Contractor may be required to adjust his method statement for approval/acceptance by
the Engineer.
No production work may commence until the efficacy of the dewatering system has been demonstrated and the systems are installed and
functioning as desired.

c) Permits wayleaves and disposal of water discharge
The Contractor shall be responsible for the timeous submission of all the applications for obtaining the requisite permits and wayleaves for
discharging wastewater from dewatering activities where such may be required all in terms of the provisions in Clause A1.2.3.22 of Chapter 1.
The Contractor shall provide all temporary ground surface piping necessary to convey dewatered water discharge to the approved discharge
point. Discharging directly onto the ground surface shall not be allowed unless approved by the Engineer.
The Contractor shall dispose of water from the works area in a suitable manner without damage to adjacent properties or facilities. Water shall
be filtered to remove sand and fine soil particles before disposal into any drainage system. Should contaminated water be encountered, no water
shall be discharged without appropriate treatment for adverse contaminants or alternative disposal. No water shall be drained in work built or
under construction.
A12.12.7.2 Process
a) Operational requirements
The system shall be in place and fully operational and ground water lowering proven to have achieved the specified reduced levels, 24 hrs prior
to commencing with any excavation or other construction activity. If required the system shall be operated continuously 24 hours a day, 7 days a
week once excavation/ construction has commenced, irrespective of whether construction activities are interrupted or temporarily halted, and fully
operational until such time as construction activities are completed and the excavations have been completely backfilled, which backfilling shall
have been tested for compliance with the specification and approval by the Engineer.
Generally dewatering by sump creation and pumping is an ongoing activity as excavation proceeds. Unless specifically provided for and instructed
by the Engineer to address sudden and unforeseen surges of water inflow into excavation separate payment will not be made therefore.
The Contractor shall at all times have, on the work site, sufficient dewatering equipment for immediate use, including standby pumps and
generators for use in case any of these items of plant breakdown and require replacement.
If the dewatering system shuts down or if pumping is suspended, for any reason whatsoever the Contractor shall withdraw from the excavation
before water levels start to rise. On resumption of dewatering, the groundwater levels will need to be re-lowered to the specified level before
continuing any construction, including excavation or backfilling.
Any in-situ material /backfill that is subjected to groundwater and wetted shall be tested as directed by the Engineer, to confirm that the condition
thereof is stable and acceptable prior to placement of further backfill and/or other construction activities. The Contractor shall remove and replace
adversely affected material with suitable material approved by the Engineer at his own expense.
Due care shall be taken when turning off the dewatering system to prevent upsurge in ground water which may weaken the subgrade of the
completed excavation.
Surface runoff shall be diverted away from excavations by site grading to promote drainage away from any excavation. Surface water shall be
collected in shallow trenches around the perimeter of the excavation, drained to sumps, and pumped or drained by gravity to maintain an
excavation free from ponding water. In the case of multistage dewatering, this would require a perimeter drain to be in place at the toe of each
excavated stage and for the collected water to pumped back to surface into the water discharge system.
Adequate control shall be maintained by the Contractor to ensure that the stability of excavated slopes are not adversely affected by water, that
erosion is controlled and that flooding of excavation or damage to structures does not occur. The Contractor is solely responsible for site
excavation safety and compliance with OHS regulations.
If the planned groundwater reduction levels are reached, but notwithstanding unstable conditions and/or unacceptable excavation invert conditions
are present, the Contractor shall either increase dewatering pumping rates and/or to install additional wells to lower the groundwater to a revised
requisite level. The Contractor should achieve the revised groundwater level lowering and stable and acceptable invert conditions before
continuing with construction.
Buoyant ground conditions shall be prevented by the Contractor by maintaining a positive and continuous removal of water. The Contractor shall
be fully responsible for all damages which may result from failure to adequately keep excavations dewatered.
A12.12.7.3 Monitoring ground water levels and potential settlements

Where so specified the Contractor shall provide groundwater monitoring at least two points/observation wells diagonally disposed at either
extremity of the excavation to a depth of at least 300 mm below the elevation of the minimum required and adequately spaced intervals in the
case linear advancing excavations. Groundwater levels shall be monitored to gauge if the specified reduction in ground water levels has been
achieved.
For deep excavations where staged descending dewatering is required, further monitoring shall be required for each stage and shall be subject
to the approval of the Engineer. In the event of linear advancing excavations such as pipeline and/or buried services, paired ground water
monitoring points/observation wells on either side and straddling the trench shall be provided at least every 30 m along the length of the trench,
or as specified in the project specification or instructed by the Engineer. Ground water monitoring points/observation wells shall be installed
timeously before the advancing excavation. Confirmation that the required drawdown has been achieved shall be obtained before the excavation
is allowed to encroach closer than 10 m from the monitoring station.
Where dewatering is required to be undertaken in the vicinity of any settlement sensitive structures, infrastructure and services, the Contractor
shall establish a grid of survey beacons within the potential zone of draw down as established from test sections and/or ground water modelling.
These beacons shall be monitored by a surveyor on a daily basis using precise levelling methods to an accuracy of ± 0,5 mm. The results shall
be processed and presented on a daily basis in the format required by the Engineer.
The Engineer may instruct that observation wells be installed at selected strategic locations outside the excavation area to monitor the draw-down
of the ground water resulting from the dewatering activities.
The Engineer will determine the allowable settlements for each potentially settlement sensitive structure or infrastructure. The Contractor shall
suspend dewatering if these critical limits are reached, before they can be exceeded. The Contractor shall liaise with the Engineer on the
implementation of the contingency plan and/or what further actions are required before dewatering may continue.
A12.12.7.4 Monitoring ground water discharge

Where so specified, the Contractor shall provide and incorporate a clean tapping device at each well location to allow easy sampling of discharge
water in accordance with the approved water quality sampling and testing programme.

Where so specified, samples shall be evaluated to detect the presence of any fine sand and/or silt that may indicate subsurface soil is being
removed by the dewatering operations. If any well produces fines, it shall be immediately shut down and the filter requirements be reviewed and
addressed. This may require that the filter of the existing well needs to be replaced or improved and that a new well be installed adjacent to it
with a revised filter design which eliminates the pumping of fines.
If so specified samples for chemical testing and analyses shall be dispatched and reach the approved laboratory within 6hrs of sampling, or as
If concentrations of tested groundwater quality parameters exceed those allowable the Contractor shall suspend the dewatering and immediately
notify the Engineer and the appropriate authority and supply them with the results so as to requisite details to determine measures and/or treatment
that are required.
A12.12.7.5 Records
well point provide a record, in a format agreed with the Engineer prior to the commencement of the work. Where such records are of an ongoing
nature the Contractor shall regularly produce reports summarising criteria and recording trends, as may be required by the Engineer.
All dewatering systems shall be checked for compliance with the specifications. Any system, or element(s) of a system, not meeting the specified
criteria, or which does not reach the specified depth may be rejected by the Engineer who may order that it be amended to conform or be replaced
if so required, to conform to the requirements.

B12.12 CONSTRUCTION DEWATERING
CONTENTS
B12.12.1 SCOPE
B12.12.3 GENERAL
B12.12.5 MATERIALS
B12.12.1 SCOPE
B12.12.3 GENERAL

B12.12.5 MATERIALS



C12.12 CONSTRUCTION DEWATERING
(i) Preamble
pay items.
C12.12.1 Establishment on site for construction dewatering lump sum
The unit of measurement shall be by lump sum.

The tendered lump sum for dewatering shall include full compensation for establishing all necessary plant and equipment on site to carry out the
works and for the removal from site of all such plant and equipment including all temporary works such as access roads, furrows and earth berms,
clearing and grading and reinstating the site on completion of the works as specified.
The work shall be paid as a lump sum, 50 % of which shall be due when all equipment is on site tested and functional, trials are completed and
the first production dewatering well ring/line is installed to the satisfaction of the Engineer and fully operational. The second instalment of 25 %
shall be payable after half the billed value of the work is complete and measured for payment and the final 25 % instalment after all the work is
complete, all plant and equipment is removed from site and the site has been reinstated to the satisfaction of the Engineer.
No extra payment shall be made for establishing any additional plant should the originally established plant not be capable of achieving the
requisite results.

C12.12.2 Installing and commissioning all requisite plant and equipment to undertake dewatering number (No)
by well system offered (type of well system to be nominated by tenderer)
The unit of measurement shall be a standard length section of header pipe with all the requisite number of wells at the dewatering location, all
fittings, materials and dewatering pump(s).
The quantity measured shall be the number of standard pipe lengths installed and commissioned in compliance with best practice and the
requirements of these specifications.
The tendered rate shall include full compensation for all costs involved in installing all equipment, pre-drilling, drilling, jetting or any other means
necessary and approved for installing all wells required at the dewatering location to achieve the required level of drawdown, complete with the
requisite filters, screens and casings in all materials and their subsequent extraction, or abandonment if approved by the Engineer, on completion
of dewatering. The tendered rate shall furthermore include for the supply and installation of all caps, riser pipes, flexible swing joints, stop valves,
couplings, well take-off points, flow meters, header pipes and dewatering pumps fully equipped with motors. Where electric motors are used to
drive the motors, the tendered rate shall include for all costs of establishing the requisite electrical supply, either from mains or by way of
generators. The rate shall also include the provision of all requisite standby equipment and the installation of all requisite, monitoring wells/points
and survey monitoring beacons as specified.
C12.12.3 Operate and maintain well system (type of well system to be nominated by tenderer) (pumped) hours) (hrs)
The unit of measurement shall be the number of hours pumped.

The quantity measured shall be the sum of the number of hrs pumped by each discharge pump for each 60m section.
The tendered rate shall include for all costs to operate and maintain the complete installation, including 24hr/7 days per week requisite supervision
and operators, all repairs and maintenance, replacement of faulty equipment and plant, cost of all fuel and/or electricity. The tendered rate shall
furthermore include for the monitoring the excavations and ongoing surveying of the settlement beacons and monitoring and reporting on the
observation wells.
C12.12.4 Supply Install and remove discharge pipeline to the required depth (diameter and class metre (m)
indicated)
The unit of measurement shall be the metre of pipeline installed.
The quantity measured shall be the actual length of discharge pipe installed from the position of the dewatering pump to the approved disposal
site(s) along the approved route.
The tendered rate shall include for the supply and installation of all pipe together with stop valves, couplings, and flow meters if required. The
rate shall also include for the protection and securing the discharge pipeline in, on and over all terrain as well the cost of securing the discharge
end, including the requisite scour protection resulting from the water discharge.
The tendered rate shall include for all costs to operate and maintain the discharge pipeline, including 24hr/7 days per week requisite supervision
and operators, all repairs and maintenance, replacement of al damaged pipe.
C12.12.5 Install ground observation wells to the required depth (diameter and class indicated) metre (m)
The unit of measurement shall be the metre of observation well installed.

The quantity measured shall be the actual total length of observation well installed as specified and approved by the Engineer.
The tendered rate shall include for the supply and installation of all material and for the provision of protective caps.
C12.12.6 Monitoring of lowering of ground water levels Lump sum
The tendered lump sum shall include full compensation for monitoring the groundwater levels as specified.
C12.12.7 Monitoring of potential settlements Lump sum
The tendered lump sum shall include full compensation for the monitoring of settlements as specified.
C12.12.8 Monitoring quality of groundwater
C12.12.8.1 Monitoring of silt and fine sand Lump sum
C12.12.8.2 Monitoring of groundwater chemistry and quality Lump sum
The tendered lump sum shall include full compensation for the monitoring of the quality of groundwater as specified

D12.12 CONSTRUCTION DEWATERING
CONTENTS
D12.12.1 SCOPE
D12.12.2 GENERAL

South Africa
COTO
Officials


October 2020

FOREWORD

Published by:

industry.
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Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 13: STRUCTURES............................................................................................................................... 13-1
13.1 FOUNDATIONS ............................................................................................................................................. 13-1
13.2 FALSEWORK, FORMWORK AND CONCRETE FINISH ........................................................................... 13-23

13.3 STEEL REINFORCEMENT .......................................................................................................................... 13-37

13.4 CONCRETE .................................................................................................................................................. 13-45

13.5 PRESTRESSING .......................................................................................................................................... 13-74

13.6 BEARINGS ................................................................................................................................................... 13-91

13.7 JOINTS ....................................................................................................................................................... 13-104

13.8 ANCILLARY STRUCTURAL ELEMENTS................................................................................................. 13-117

13.9 STRUCTURAL STEELWORK FOR MINOR STRUCTURES.................................................................... 13-127

13.10 PAINTING OF MINOR STRUCTURES .................................................................................................... 13-136

13.11 STRUCTURAL STEELWORK FOR MAJOR STRUCTURES ................................................................. 13-146

PART A: SPECIFICATIONS ....................................................................................................................................................................... 13-146
13.12 STRUCTURAL STEEL PROTECTIVE TREATMENT OF MAJOR STRUCTURES ............................... 13-161

13.13 INCREMENTAL LAUNCHING OF BRIDGE DECKS .............................................................................. 13-179

13.14 SPECIALIST STRUCTURES ................................................................................................................... 13-192

13.1 FOUNDATIONS
CONTENTS
A13.1.1 SCOPE
A13.1.2 DEFINITIONS
A13.1.3 GENERAL
A13.1.5 MATERIALS
A13.1.8 WORKMANSHIP

A13.1 FOUNDATIONS
A13.1.1 SCOPE
This Section covers foundation and foundation related work which, for the purposes of these specifications, shall comprise amongst others those
elements of construction below the level of the bottom surface of conventional spread footings, pile-capping slabs or caisson cover slabs,
collectively hereinafter referred to as base or bases, and it covers all the associated permanent and temporary works. Piling is dealt with in
Chapter 12. Foundations for prefabricated culverts are not included but are specified in Chapter 3.
A13.1.2 DEFINITIONS
Artificial islands - temporary platforms constructed in rivers and streams to allow access for construction activities.
Banks - a stream bank or river bank is the terrain alongside the bed of a river.
Watercourse - a watercourse means a river or spring; a natural channel in which water flows regularly or intermittently; a wetland lake or dam,
into which or from which water flows; and any collection of water that may be declared to be a watercourse in terms of relevant legislation.
Caissons - a watertight retaining structure used, to facilitate founding of bridge structures as an alternative to piling.
Cofferdams - a cofferdam is a temporary enclosure built within a body of water, in waterways, on waterlogged areas or on unsuitable ground
and is constructed to allow the enclosed area to be pumped out, creating a dry work environment for the construction of permanent works to
proceed.
DWS - Department of Water and Sanitation.
Contractor’s Competent Person (CCP) - the Contractor’s Competent Person is appointed in writing to administer, inspect and verify the
adequacy of temporary work such as excavations and sub-structure work must be registered and competent in relation to the services rendered
in terms of the ECSA Engineering Professions Act and construction regulations as contained in the OHS.
A13.1.3 GENERAL
A13.1.3.1 Subsurface data
The Contractor shall take due cognizance of available information regarding site geotechnical conditions and related stability and safety of the
excavations. Provision for specialised support systems shall be included in appropriate payment items. If such separate items are not provided
they shall be deemed to be included in rates for excavation items.
The provisions of the General Conditions of Contract shall apply with regard to any information supplied regarding any subsurface conditions
likely to be encountered.

If it is found during the course of excavating, or caisson work, that the soil or founding conditions differ greatly from those shown on the
drawings, the Contractor shall immediately notify the Engineer.
The Engineer shall, whenever he may deem it necessary during the course of excavation, be entitled to call on the Contractor to conduct
additional foundation investigations or tests at, or below, the respective founding levels aimed at establishing safe bearing conditions and
founding depths. Payment for these investigations shall be made by means of the Provisional Sums provided.
Where the actual foundation conditions encountered are considerably at variance with conditions visualised and described in the contract
documents and to the extent that those terms for which the rates or prices provided for in the contract are rendered unreasonable or
inapplicable, such other rates or prices consistent with the rates set out in the contract shall be fixed as provided for in the conditions of contract.
This is subject always to a founding depth variation not exceeding 2,5 m of the foundation base level of the permanent structure as specified
shall not, by itself, be held to constitute cause for variation for the contract rates or prices.
A13.1.3.2 Channel preservation

a) Work on, over, in or adjacent to watercourses
(i) General
The flow of the stream and conservation of marine and freshwater life shall be maintained at all times in accordance with the EMP.
Access to cofferdams and artificial islands shall be effected without unnecessarily disrupting the flow of the stream at the point of
crossing, unless otherwise specified.
On completion of the work, surplus excavated materials, including materials excavated from caisson compartments and materials
used in cofferdams and other temporary works, as well as in situ material, shall be removed and disposed of by the Contractor to
the level of the original bed or such elevation as specified or as required for stream channelization.
Special authorisation may be required in terms of applicable legislation for undertaking certain water use activities. These activities
may include impeding or diverting flow of water in a watercourse or altering bed, banks, course or characteristics of a watercourse,
pollution of water resources or the use of naturally occurring water for construction activities. These requirements shall be
specified in the project related Environmental Management Programme.
(ii) Access requirements
As far as reasonably possible, the Contractor shall use existing access paths, tracks and roads to access the construction site to
reduce impact thereof. Where no access exists, the Contractor shall take cognizance of sensitive areas (e.g. surface water,
natural vegetation, steep banks, etc.) when determining location of access.
As far as reasonably possible, work within a river shall take place outside the rainy season, preferably when flow is at its lowest.
During construction of river bridges or structures within a river, the Contractor will only be permitted to construct, subject to the
requirements of the EMP, low level causeways to access the rivers that cause negligible backing up; and cofferdams around the
piers, abutments or other elements for the construction of the foundations. These obstructions must be removed at the end of the
contract and the river and banks restored to their original condition.
(iii) Erosion and sedimentation prevention
The Contractor shall exercise sedimentation and erosion control to the satisfaction of the Engineer. The Contractor shall protect
areas susceptible to erosion by installing the necessary temporary and permanent drainage works. The Contractor shall
implement measures to prevent migration of fill material from works to existing water bodies. The Contractor shall ensure that any
pumped water from foundation excavation, flooded works, etc., passes through a sediment-settling facility before entering the
watercourse.
(iv) Water quality requirements
The Contractor shall, if required by the project specification, undertake water quality measurements of the river. The
measurements shall be of pH value, turbidity, electrical conductivity and temperature. Sampling and testing shall be undertaken on
specified periods for the duration of the project at sampling points selected prior to construction. Monthly water samples should be
obtained during the duration of the project and sent to an accredited laboratory for analysis of the same parameters as for daily
measurements. Specific acceptable limits for river water quality below the construction site shall be in accordance with the DWS
water quality guidelines, or, in case the watercourse in issue already contains contaminated water, the downstream quality shall
not at any given time be worse than the upstream quality. Measurement and sampling results shall be presented to the Engineer
and environmental control officer as deemed necessary by the Engineer.
(v) Wastewater requirements
The Contractor shall prevent pollution of surface or groundwater from the release, accidental or otherwise of contaminated water
as a result of construction activities. The Contractor shall be responsible for the construction and operation of the necessary
collection facilities in order to prevent such pollution or settlement of suspended matter, and shall dispose of the collected waste
as approved by the Engineer.
(vi) Use of natural water sources for construction activities
Unless otherwise authorised by the Engineer, the Contractor shall not be permitted to utilise any natural occurring water for
construction activities.
A13.1.3.3 Compliance with legislation

In all instances the work performed under this Section shall comply fully with the requirements of applicable legislation and regulations which
include the following:
a) Environmental Management Programme
b) Occupational Health and Safety Act and Construction Regulations

The method statements and typical drawings submitted by the Contractor with his tender submission where specified, describing key facets such
as method, key plant, materials, personnel and, programme constraints of the envisaged construction process, shall form the basis for the
detailed method statements required for the works to be executed on the project.
These method statements shall be prepared and submitted to the Engineer for approval for each facet of the work at the start of construction,
within time scales specified. The onus lies with the Contractor to ensure that the information is gathered and associated activities are completed
expeditiously so as to avoid any delays in the commencement, continuation and completion of the required works. Unless otherwise specified or
provided for in the Contract Documentation no permanent works shall be commenced until the Engineer’s approval has been obtained. Due
allowance shall be made for obtaining alternative materials, resubmissions and redesigns, all to the required/approved standards, methods and
practises in attending to these requirements. Particular attention shall be paid to the early submission of materials-, concrete- and grout mix
The Contractor shall, however, remain responsible for all work-methods, materials, plant and equipment used, notwithstanding acceptance by
the Engineer.
A13.1.3.5 Hold points

The Contractor shall comply with the specified hold points relating to approvals required from the Engineer. A hold point is a stage of the work,
where the Engineer’s approval is required, before commencement or continuance of that particular activity by the Contractor, is permitted.
Project specific requirements will be included in the Contract Documentation or agreed upon between the Engineer and the Contractor.

A13.1.4.1 General
In the following instances where design details of temporary works are required, these shall be performed by an ECSA-registered Professional
Engineer or Professional Technologist with the relevant experience, in accordance with the appropriate specifications and codes. The Contractor
shall submit these site design details to the Engineer for his approval at least 30 days before commencement of the applicable activity.
The Contractor shall ensure that all temporary works undertaken shall comply with the relevant sections of the Occupational Health and Safety
Act and the Construction Regulations.
It is a requirement that all temporary works shall be finally inspected and signed off by the CCP, who shall be an ECSA registered Professional
Engineer or Technologist with relevant experience, before the permanent works commence.
Unless provided for separately, any additional costs for these pre-approval requirements shall be included in the tendered rates.
A13.1.4.2 Drainage systems

Drainage systems, such as external well point systems for excavations, shall comply with relevant applicable requirements and shall take due
cognizance of the existing soil profile, existing water table and possible river water levels which may occur during construction.
The Contractor shall provide complete details of proposed drainage systems and design details for any location where the appropriate system is
required.
A13.1.4.3 Cofferdams
The design and construction of cofferdams other than those comprising earth embankments, shall comply with the requirements of BS 8004.
Before starting with construction, the Contractor shall submit drawings to the Engineer, which show details of cofferdams and method of
construction, for his information. All risks related to such cofferdams, including the risk of flooding, shall remain exclusively with the Contractor.
A13.1.4.4 Excavation support systems

The Contractor shall provide complete details of proposed shoring systems or temporary earth retaining systems including a design details for
any location where the relevant system is required.
The Contractor shall ensure all excavation work is carried out under the supervision of the CCP who was appointed in writing for that purpose.
The CCP shall, as far as is reasonably practicable and applicable, assess the stability of ground before excavation work begins and as the
excavation proceeds strictly in accordance with the applicable OHS regulations. All risks related to such support systems shall remain
exclusively with the Contractor.
A13.1.4.5 Temporary access roads

In the event that no existing roads or tracks can be utilised to access the site of the foundation works, proposals for access roads shall be
submitted to the Engineer for approval prior to starting any work on the access. If such access road will affect any property or facility outside the
road reserve, the proposals shall include written consent from the affected landowner. For details, refer to Clause A4.1.7.1 of Chapter 4.
All such temporary access shall be at the Contractor’s cost.

A13.1.5 MATERIALS
A13.1.5.1 General
Material used in the permanent foundation work shall comply with the requirements specified for the particular material in these specifications.
A13.1.5.2 Banks and artificial islands

The Contractor may use any material deemed suitable with due consideration of requirements of the EMP and for water quality.
A13.1.5.3 Rock (for rock fills and plums)

Rocks shall be clean, hard, angular, veld or quarry stones of such quality that they will not disintegrate on exposure to water or weathering.
Cobbles and river boulders shall on account of their rounded shape, not be used unless authorised by the Engineer. The rock shall be free from
soil, shale, mudstone, basalt and dolomitic soft rock or organic material. Neither the breadth nor thickness of a single stone shall be less than
one-third its length. Not more than 10 % of the total volume of rock fill shall consist of rock with a mass of less than half the specified mass and
not more than 10 % of the total volume of rock fill shall consist of rock with a mass of more than 5 times the specified mass. At least 50 % of the
total volume of rock fill shall consist of stones the mass of which exceeds the specified mass. The minimum specified mass for rock fill shall be
150 kg and for rock plums shall be 50 kg.
A13.1.5.4 Crushed stone

Crushed stone used for the construction of crushed-stone fill shall originate from sound unweathered rock approved by the Engineer.
A13.1.5.5 Granular fill

Granular material used for constructing compacted granular fill under foundations and behind retaining structures shall be approved G5 quality
material or better.
A13.1.5.6 Grouting
a) Cementitious grout
Cementitious binder for grout shall meet the appropriate requirements of Clause A13.5.5.7.
b) Proprietary-brand, and chemical, grouts
Proprietary-brand, and chemical, grouts shall be prepared and used strictly in accordance with the manufacturer’s instructions and as specified
in the applicable Sections of Chapter 14.
A13.1.5.7 Plum concrete

Plum concrete shall consist of either mass concrete with plums in which rock plums are placed into wet concrete protruding into the concrete
layer or prepacked concrete in which the rock plums are placed and the concrete placed over and around the plums. Mass concrete or
prepacked concrete shall comply with the requirements of Section A13.4 and have a characteristic strength of at least 25 MPa. The water to
cementitious binder ratio shall be designed to maintain the flow ability of concrete and to fill all interstices between the rock plums. The rock size
used for plums shall be between 200 and 300 mm and they shall meet the requirements for rock as specified in Clause A13.1.5.3. The
proportion of plums shall not exceed 60 % of total volume of plum concrete. The plums shall be laid in layers using mortar or flowable concrete
to fill all interstices. Plums shall extend above each layer to prevent slip planes between layers. Concrete slush and laitance shall be wire-
brushed off proud rock surfaces at day joints between layers. All plum concrete shall be maintained wet for curing purposes for at least 7 days.
A13.1.5.8 Soil cement

Soil cement shall consist of at least C2 quality material as specified in Clause A4.1.5.14 of Chapter 4 or as specified in the project specification,
with a cement content which shall not be less than 3 % if handled and compacted with a similar technique to granular materials or 5 % if handled
and compacted with a similar technique to concrete respectively.

The Contractor shall, before construction commences, provide comprehensive details of all plant and equipment, which shall be appropriate for
intended use. It shall be clear from the information provided that the required production rates and activities as indicated in the approved
construction programme can be achieved.

A13.1.7.1 Work access and drainage
a) General
This Clause covers the provision of access for the proposed construction activities, which include the construction of access ramps, work
platforms, artificial islands and cofferdams. This Clause also covers draining of excavations. The Clause is aimed at conventional construction
activities and shall be applicable unless otherwise specified in the Contract Documentation.
The Contractor shall prepare a method statement setting out the proposed approach and methodology for providing the necessary access and
drainage. This method statement shall take into account the requirements of the Contract Documentation and in particular the requirements and
limitations imposed by the environmental specification in general and specific to the site in question. The Contractor may not commence with the
construction of accesses until he has obtained the Engineer’s written permission to proceed.

After completion of the permanent works, all temporary works shall be completely removed, the ground levelled and the site left neat. Where this
is impracticable, such remaining portions that have not been removed, shall be dealt with in accordance with the Contract Documentation.
b) Work access
(i) Banks and artificial islands
Where temporary banks or artificial islands are constructed in view of affording access to locations where structural members,
piling or caissons are to be constructed, banks or islands shall be adequately compacted in view of supporting any plant and
material, without any undue settlement that may have an unacceptable effect on the end product.
The Contractor may use any material complying with the requirements of Clause A13.1.5 and deemed by him to be suitable for
constructing banks and islands, but he shall note that no separate payment shall be made for any works in terms of payment items
in Chapter 12 for any obstructions or hard material occurring in the placed material used.
On completion of the work, the Contractor shall remove banks and artificial islands and reinstate the site as near as possible to its
original condition in compliance with the EMP.
(ii) Cofferdams
Where necessary, if it is impracticable to dewater a foundation by pumping methods, cofferdams shall be constructed in
waterways, on waterlogged areas and on unsuitable ground to facilitate construction of the permanent works in the dry, to ensure
the lateral stability of or to retain the surrounding material and to the protect work under construction against flooding. The
Contractor shall not commence with the construction of a cofferdam until he has obtained the Engineer's written permission to do
so.
Cofferdams may be constructed in many ways using materials complying with Clause A13.1.5 as suitable for the particular site
circumstances. In the case of river structures, where large areas are required it will usually take the form of earth embankments
and where smaller areas, such as foundation bases, are required, interlocking metal sheeting (sheet piles) may be used if feasible.
In the latter, cofferdams shall be adequately braced, weighted and anchored and shall be as watertight as practicable. A concrete
foundation seal shall be required before the cofferdam is dewatered.
Cofferdams shall be completely removed upon completion of permanent work except that if, in the case of sheet pile cofferdams,
the Engineer is of the view that the dislodgment of sheets may disturb the foundation of the permanent structure, the sheeting will
be cut at a level instructed by the Engineer, and the lower part will be left in place.
c) Drainage
The Contractor shall apply suitable, effective drainage methods for preventing the ingress of water into excavations and to keep them dry. The
preventative measures shall include construction and maintenance of intercepting and diversion berms and drainage channels, with all channels
effectively draining towards lower-lying natural drainage routes or sumps, with all necessary bailing and pumping equipment supplied, operated
and maintained by the Contractor. The preventative measures shall ensure that the foundation excavations are dewatered sufficiently to allow
the necessary construction operations to be properly executed.
The drainage measures, with the exception of pumping, shall be maintained until the backfilling has been completed. Between the various
construction stages, pumping may be temporarily interrupted in consultation with the Engineer.
Any draining or pumping of water shall be done in a manner which precludes concrete or materials or any part thereof, from being carried away.
Any damage to the work in progress due to failure of drainage systems or flooding are exclusively the Contractor’s risk.
A13.1.7.2 Excavation
a) General
This work shall include excavations not provided for elsewhere in these specifications, which are required for founding the structures as well as
for excavation required in respect of demolition, extension or modification of existing bridges and culverts.
Excavation in the vicinity of existing structures and road formations shall be performed with due care and diligence. The Contractor shall take
special care not to disturb the founding material of any existing foundations and road formations. The excavation profile must strictly be as
approved by the Engineer and as shown on drawings.
b) Agreed excavation surface level and profiles
Prior to commencing with any excavation, artificial islands, cofferdams, temporary banks or any other works covered by this specification, the
Contractor shall notify the Engineer in good time to ensure that levels be taken of the undisturbed ground surface for determining a ground
surface from where excavation shall be measured, and this ground surface shall be agreed on by Engineer and Contractor.
In addition, the proposed excavation profile, with due consideration of stability of material, existing structures and existing road formations shall
be agreed prior to commencement of excavation. Details of lateral support systems, if any, shall be provided and approved in accordance with
all the requirements for temporary works and site designs.
The final foundation depth and suitability of the foundation material shall be approved by the Engineer in consultation with a suitably–qualified,
ECSA–Professional Registered Geotechnical Engineer.
c) Excavation
In stable or hard material the Engineer may approve that the excavated surfaces can act as forms for casting of the concrete and the
excavations shall then be carried out and trimmed to neat dimensions of the concrete members shown on the drawings. To prevent moisture
loss in the concrete where excavated surfaces act as forms, a foundation lining shall be installed as specified in Clause A13.1.7.9. As an
alternative, provided that sufficient space is made available during excavation, an additional 50 mm of concrete cover, over and above that
specified may also be provided if approved by the Engineer. Excavations in soft material in excess of the authorised dimensions (over-
excavation) or overbreak in hard material shall be backfilled with the same class of concrete as that in the base.

In the case where excavations are made to neat dimensions of the concrete members (no formwork), compensation for the backfill of over-break
in hard material shall be measured and paid for under pay item C13.1.9 but the cost of backfilling of over-excavation in soft material shall be at
the Contractor’s own expense. In soft material, the final 0,5 m and in hard the final 0,25 m, shall be removed using suitable hand equipment
such as pick and shovel or pneumatic tools to cause minimum disturbance to in-situ founding material. Such hand excavation shall be measured
and paid for under payment pay item C13.1.4 4 Where additional excavation width is required for the erection of formwork, no additional
compensation for over-excavation or overbreak will be made except as provided for the applicable payment items.
Where blasting is required, the Contractor shall complete the entire foundation excavation before commencing with the construction of any
permanent concrete work, unless otherwise approved by the Engineer.
Boulders, logs or any other unsuitable material excavated shall be spoiled.
When material suitable for founding is encountered at or before the specified founding level, it shall be cut and trimmed to a firm surface, either
level, stepped or serrated, as may be required.
Where, in the opinion of the Engineer, unsuitable material is encountered at founding level, such material shall be removed and replaced with
foundation fill in accordance with Clause A13.1.7.6 and to dimensions and depths as directed by the Engineer. Alternatively, the Engineer may
order revised founding levels, based on an assessment of the exposed founding conditions. Unless such new founding depth varies from the
specified founding level by more than 2,5 m, it shall not be considered as a variation in terms of the Contract.
d) Classification of excavated material
For payment purposes distinction shall be made between excavation in hard and soft material. All excavation for the foundations of structures
shall be classified in accordance with the following classification:
(i) Hard material
Boulders with a volume of 0,1 m 3 or more;
or
material which cannot be excavated except by drilling and blasting or by using pneumatic tools or mechanical breakers.
(ii) Soft material
All material not classified as hard material, shall be classified as soft material.
e) Blasting
Where blasting is permitted, it shall be carried out in accordance with the requirements of Clause A1.2.7.5 of Chapter 1 and Section A12.10 of
Chapter 12.
f) Deterioration of foundation excavations
Where soft or hard material, which quickly deteriorates when exposed, is encountered at foundation level, the excavation shall be excavated and
trimmed to final slope and level and the blinding placed within four hours after completion of the excavation.
Where bottoms or sides of excavations, in which bases are to be cast, are softened on account of negligence by the Contractor in allowing storm
or other water to enter the excavations, this softened material shall be removed and replaced with foundation fill as directed by the Engineer, at
the Contractor's expense.
g) The safety and protection of excavations
The Contractor shall take all necessary precautions to safeguard stability and safety of excavations, adjacent structures or road formations.
Personal safety shall not be jeopardised, neither shall any situation be allowed which may result in damage of whatsoever nature to the
temporary or permanent work.
Precautionary measures taken by the Contractor shall strictly comply with provisions of the Health and Safety Act, and Construction Regulations.
Without derogating from the importance of any provisions, the Contractor shall give due attention to:
• Execution of excavation work under supervision of a CCP,
• Stability of excavations and need (or otherwise) to provide sufficient and suitable shoring or bracing,
• Provision of an effective barrier or fence along the perimeter to safeguard workers, the public and where appropriate, vehicles,
• Prevention of run-off and surface drainage water from entering the excavations,
• Refer to detailed requirements provided in the Contract Documentation.
The Contractor who performs excavation work, shall take reasonable and sufficient steps in order to prevent any person from being buried
or trapped by a fall or dislodgement of material in an excavation. No persons shall work in an excavation which is not adequately shored or
braced. Shoring and bracing are not required where sides of excavations are sloped to safe angles as determined and detailed in writing by
the Engineer in consultation with a suitably-qualified, ECSA-registered geotechnical Engineer.
Shoring or bracing shall be designed with a suitable margin of safety and constructed in a manner to ensure this value.
No load, material, plant or equipment shall be placed or moved near the edge of any excavation where it may cause collapse and consequently
endanger safety of any person, unless precautions such as provision of sufficient and suitable shoring or bracing are taken to prevent the sides
from collapsing.
Where stability of an adjoining building, structure or road is likely to be affected by making an excavation, steps shall be taken to ensure stability
of such building, structure or road and safety of persons. Such special measures may be specified in the Contract Documentation but the
identification and installing of such measures remains the Contractor’s obligation regardless.
Convenient and safe means of access shall be provided to every excavation in which persons are required to work, and such access shall not
be further than 6,0 m from the point where any worker within the excavation is working.
The Contractor shall ascertain, as far as is reasonably practicable, the location and nature of electricity, water, gas or other similar services
which may in any way be affected by work to be performed, and shall before commencement of excavations that may affect any such service,
take the steps necessary to render circumstances safe for all persons involved, and to protect such services according to the respective service
authority’s wayleave or work permit conditions.
The Contractor shall ensure that every excavation, including all bracing and shoring, is inspected (i) daily, prior to commencement of each shift,
(ii) after every blasting operation, (iii) after an unexpected collapse or settlement of ground, (iv) after damage to supports, and (v) after rain, by
the competent person in order to ensure safety of excavations and persons. The inspection results shall be recorded in a register kept on site
and made available on request to an inspector, client, Engineer or, any other Contractor or any employee.
Every excavation accessible to the public or adjacent to public roads or thoroughfares, or whereby the safety of persons may be endangered,
shall be (i) adequately protected by a barrier or fence of greater than 1,0 m height and as close to the excavation as is practicable, and (ii)
provided with warning illumination or any other clearly-visible boundary indicators at night or when visibility is poor, or any other suitable and
sufficient precautionary measures where (i) and (ii) are not practicable.
Any person entering any excavation shall comply with precautionary measures stipulated for confined spaces as determined in the Regulations.
Where excavation works involve the use of explosives, the Contractor shall appoint a competent person in explosives for excavation, and shall
ensure that a method statement is developed by that person in accordance with the applicable explosives legislation, all as specified in Chapter
1.
If at any stage during excavation inflow of groundwater is perceived to render the work dangerous, the Contractor shall immediately instruct the
evacuation of an excavation until the CCP has inspected the excavations and instructed appropriate actions.
h) Inspection
No concrete shall be placed before excavations are properly cleaned and dewatered by the Contractor and inspected and approved by the
Engineer.
i) Excavation by hand
Where circumstances prevent the use of mechanical excavators and material can be removed only by hand implements, the Engineer shall
authorise supplementary payment to the Contractor for such work at the tendered rates for excavation by hand should he be satisfied that the
Contractor was unable to prevent the necessity for excavation by hand by proper planning and precautionary measures. This supplementary
rate for excavation by hand, shall not apply to minor finishing or clearing jobs in excavations done by mass excavation plant.
j) Work on, over, under or adjacent to railway lines
All work carried out on, over, under or adjacent to railway lines shall be carried out strictly in accordance with requirements of the owner of such
railway line. Specific requirements in this regard shall be included in the Contract Documentation.
A13.1.7.3 Founding
Variations during construction in anticipated founding conditions may necessitate changes to dimensions and founding levels specified or shown
on the drawings.
The Engineer has full and absolute power in terms of the contract to order such variations and to specify actual founding level for each
foundation fill, base or caisson during construction.
The Contractor shall not be entitled to any additional payment in consequence of any such variation in dimensions or founding depths over and
above that provided in Clause A13.1.3.1 irrespective of stage of construction at which the instruction to alter the dimensions or founding depths
is given.
No bases or caissons shall be founded unless authorised by the Engineer. Each founding level shall be accurately measured, recorded and
agreed.
The term "founding level" used in these specifications shall be have the following meanings in respect of:
a) Foundation fill
Surface of in situ material that was prepared to receive foundation fill.
b) Bases
Underside of base, or conversely, top of the concrete screed.
c) Piled Foundations
Underside of pile cap.
d) Caissons
Underside of cutting edge.
A13.1.7.4 Utilisation of excavated material

Excavated material and material recovered from temporary works shall, if suitable, be utilised for backfill. Material unsuitable for use as backfill
or in excess of required quantity shall be spoiled or utilised as directed by the Engineer.
Excavated material not used for backfill nor taken to spoil but used in construction of embankments or other parts of the work, as directed by the
Engineer, will be paid for under foundation excavation as well as under the relevant item for which it is used.
Excavated and stockpiled material shall be so dumped so as to not endanger incomplete structures either by direct pressure or indirectly by
overloading fills contiguous to the structure, or in any other way.

A13.1.7.5 Backfill and fill near structures
a) General
When backfill/ or fill is placed, the following precautionary measures shall be taken:
(i) The material shall be placed simultaneously, in so far possible, to approximately the same elevation on both sides of an abutment, pier, or wall
where appropriate. If conditions require backfill or fill to be placed appreciably higher on one side than the other, additional material on the
higher side shall not be placed until authorised by the Engineer, and preferably not until concrete is more than 14 days old, or until tests show
that concrete attained sufficient strength to safely withstand any pressure extended by backfill or fill or the particular method of construction.
(ii) The material behind abutments, directly restrained at top by the superstructure, for example portal- or box-type structures, shall be placed
simultaneously with a maximum difference in level of 150 mm, as shown on drawings, or as directed by the Engineer.
(iii) The material behind portal walls of portal structures shall not be placed until the top slab is placed and cured, unless otherwise authorised by
the Engineer.
b) Backfill
Excavated areas around structures shall be backfilled, with approved material, G7 or G8 as specified in chapter 4, in horizontal layers less than
150 mm thick after compaction, to the level of original ground surface or to levels specified on the drawings. Each layer shall be moistened or
dried to the material’s optimum moisture content for and compacted to a density of at least 93 % MDD for soils and gravels, and at least 95 %
Maximum Dry Density (MDD) for non-plastic sands if the % passing the 0,075 mm sieve is greater than 20 % and at least 100 % MDD where
less than 20 % passes the 0,075 mm sieve.
c) Fill
Before the space between the structure and approach fill, or between the structure and faces of the surrounding excavation is backfilled, the
slope of the approach fill, or faces of excavation shall be shaped by benching or serrations to prevent wedge action from occurring between the
structure and the approach fill or excavation faces.
Distance between exposed face of the structure and toe of approach fills or excavation faces shall be sufficient to allow proper compaction. In
the event that excavations are made together with utilisation of lateral support, backfill distance will be limited to location of the lateral support
system.
d) Fill within restricted area
That part of the fill within a horizontal distance of 3,0 m from vertical and inclined concrete faces of the structure, 300 mm above bases, at least
1,0 m above roof slabs and that part between pillars of spill-through abutments or that part shown on drawings, shall be termed "fill within
restricted area". Where roof slabs span more than 1,8 m, the depth of restricted area shall be determined by the Engineer.
The quality of fill material within the restricted area shall comply with the requirements of Chapter 4 and except that it shall be compacted to a
density greater than 93 % MDD. In order to achieve the specified density, the Contractor shall, where necessary, import material of suitable
quality.
Unless otherwise directed by the Engineer, only vibratory compaction equipment that is pushed or drawn by hand or self-propelled static rollers
shall be used to achieve required density within a restricted area. Fill-in spaces inaccessible for mechanical compaction equipment below
concrete soffits shall be constructed by methods specified or approved by the Engineer.
A13.1.7.6 Foundation fill

If it is found during the course of excavation that material at indicated founding depth does not exhibit the required bearing capacity as specified
on the drawings, the excavations shall be extended at the discretion of the Engineer until satisfactory founding material is encountered. The
Engineer reserves the right to instruct the Contractor to make up the difference in levels with foundation fill.
Where foundation fill consists of rock or crushed stone, it shall be constructed in accordance with requirements in the Contract Documentation or
as directed by the Engineer.
Foundation fill consisting of granular material shall be of the quality and type specified or directed by the Engineer and be constructed in layers
less than 150 mm in thickness after compaction. Each layer shall be moistened or dried to optimum moisture content and compacted to a
density greater than 95 % MDD for soils, gravels and cohesionless sands with more than 20 % passing the 0,075mm sieve, and at least 100 %
MDD for cohesionless sand with less than 20 % passing the 0,075 mm sieve size.
In instances where possible scour or groundwater conditions could result in erosion of foundation fill, the Engineer may instruct that mass
concrete or plum concrete fill be used in which case it shall be of class or mix of concrete fill as in the Contract Documentation or as directed by
the Engineer and constructed in uniform layers less than 600 mm thick.
Unless otherwise specified or directed by the Engineer, foundation fill below footings shall extend a minimum of 500 mm beyond the horizontal
dimensions of the concrete base and constructed from mass concrete (with or without plums), graded rock, crushed stone or compacted
granular material. The width in both directions shall extend downwards and outwards at an angle of at least 45° with the horizontal from each
outer edge of the plan dimensions at the underside of the footing down to the final founding level. The foundation fill shall be built up in layers of
compatible thickness with the type of material used.
A concrete blinding, which complies with requirements shown on the drawings, shall be placed underneath all bases except where mass
concrete fill is used or where authorised by the Engineer that this need not be done. Concrete blinding shall extend a minimum of 100 mm
beyond the horizontal dimensions of the base.
In the case of structures where excessive ground water is encountered, this blinding layer may extend over the full plan area of the base of the
excavation and beyond the edge of the foundation where required.
Where mass concrete or plum concrete fill is constructed under a base, it shall be accurate to final levels of the underside of the base.
Also refer to Clause A13.1.7.9 in cases where the omission of blinding is considered.

A13.1.7.7 Grouting of rock fissures
Where specified, fissures in rock below and around bases shall be sealed by pressure grouting with either cement:water, sand-cement,
proprietary brand grout, or chemical grout as specified.
Water to cementitious binder ratio of grout shall be approved in advance by the Engineer.
Extent of fissuring shall be established via water testing under pressure to establish the Lugeon value of in situ rock mass.
Holes greater than 40 mm diameter, shall be drilled at positions indicated by the Engineer and grout shall be pumped into these holes under
suitable pressures using a casing at the mouth and a packer. Grouting shall be at 3,0 m increments to maximum depth ordered. Care shall be
taken to avoid further fracturing of rock strata by excessive grouting pressures.
Grouting rock fissures shall be conducted by specialised operators with adequate experience in this class of work who are approved by the
Engineer.
A13.1.7.8 Foundation dowels

Where required, foundation dowels of specified material, diameter and length shall be installed at positions and to dimensions shown on the
drawings or as directed by the Engineer. After exposing, clearing and trimming the rock formation, holes with specified diameters and depths
shall be drilled in the rock. Diameter of holes shall be greater than twice the dowel diameter, but never less than 40 mm. After holes are cleared
by water-jetting or compressed air and pre-wetted, they shall be filled with grout from the base so as to ensure no air pockets. Within 15 minutes
of grout-filling, the dowels shall be carefully driven into the holes. A grout with a maximum water to cementitious binder ratio of 0.40, including an
approved expanding additive, complying with requirements of Clause A13.1.5.6 shall be added.
Where chemical grout is approved, hole diameter, depth and preparation shall be in accordance with manufacturers specification and project
requirements.
The dowels, and where required corrosion protection, shall comply with the requirements of Section A13.3.
A13.1.7.9 Foundation lining

Where specified or directed by the Engineer, foundation linings shall be installed as described hereafter. The Engineer shall have the right to
order use of linings against sides of excavations and undersides of bases and slabs in lieu of formwork and concrete blinding.
All surfaces to be lined shall be covered with an approved sheeting to provide a clean impervious layer. This material shall be of sufficient
strength to provide a durable working surface and support concrete and reinforcement without tearing. Joints of material between strips shall
have a 200 mm overlap and the lining shall be held firmly in position by nails, pegs, etc.
Polyethylene sheeting with a minimum thickness of 0,250 mm is generally considered to be adequate for use below bridge approach slabs and
bases and for sides of excavations.
A13.1.7.10 Caissons
a) General
Caissons, as contemplated in these specifications, shall be hollow concrete vessels which are wholly or partly constructed at a higher level and
lowered by internal excavation or ballast to desired founding level to form structural bearing members. Caissons may be of circular, rectangular
or any other shape and may contain one or more excavation compartments, all as detailed on the drawings.
Unless otherwise specified hereafter, provisions of BS 8004 shall apply in regard to construction of caissons.
b) Construction and sinking
A firm horizontal base shall be prepared on which the cutting edge of caisson shall be laid horizontally. The level of base shall be determined
and shall be agreed by the Engineer and Contractor and shall serve as the ground surface from which the excavation inside the caisson is
measured.
Successive stages of the caisson shall be of convenient height, or as directed by the Engineer, and shall be lined accurately with preceding
stages.
If specified, all precast elements shall have adequately constructed joints in accordance with drawings to ensure a snug fit.
For in situ phase construction, all construction joints in walls shall be reinforced and joints shall be made as specified in Section A13.4.
The lowest element of every caisson, which contains cutting edges, shall be cured for at least 7 days or shall reach the specified characteristic
compressive strength before sinking is commenced. Subsequent elements shall be cast in sufficient time to ensure adequate strength for safely
resisting applied forces.
During constructing and sinking, caissons shall be maintained vertically and kept in correct positions.
Position and inclination of each caisson shall be determined accurately by measurement every 2,0 m of sinking, or after sinking through depth of
one element, whichever distance is smaller.
To eliminate excess friction, the Contractor may use bentonite or similar lubricant, or a water-jet system.
Excavation inside caisson compartments shall, unless otherwise specified herein, comply with provisions of Clause A13.1.7.2.
In multi-compartmented caissons excavation in any one compartment shall not be taken deeper than 0,6 m below that in any other
compartment, except where necessary for correcting deviations.
Cutting edges shall be frequently inspected or probed to locate obstacles, which shall immediately be removed.
The Contractor shall supply all grabs, pumps, diving gear and other plant required for sinking and founding all caissons and shall allow the
Engineer to use a diving suit and related equipment for inspection purposes, if required.

The Contractor shall employ a competent diver to carry out work under water and shall make provision in tendered rates for respective items for
this cost.
Where the caisson strikes a hard inclined layer and work must be carried out below the cutting edge, such work shall be measured and paid for
under relevant items under item C13.1.20 and, where no applicable items exist, such work shall be paid for as extra work.
Should the Contractor wish to apply pneumatic caisson methods (with a compressed air chamber) for construction, he shall furnish the Engineer
with full details of plant, equipment and method for his approval.
c) Founding
The material at founding level, if sloping or irregular, shall be cut to as nearly level as possible until the entire cutting edge is evenly and firmly
supported on the material. Subject to approval of the Engineer, blasting may be used for this purpose. If blasting is used, only light charges shall
be allowed with the caisson protected against damage by suitable cushioning.
Should the sloping surface be of hard rock which cannot be cut or broken by any safe and feasible means, the foundation shall be built up via a
solid wedge of concrete which fills the entire space between bedrock surface and the horizontal plane through the cutting edge. This concrete
shall be of the same class as that specified on the drawings or in the schedule of quantities for the concrete seal.
Rock or hard material founding material shall be completely uncovered. This founding surface shall be cleared of all loose material before
inspection by the Engineer immediately prior to casting the concrete seal.
No concrete shall be placed in the wedge or seal before the Engineer inspected and approved the foundation. For this purpose the Contractor
shall adequately dewater the caisson to enable the Engineer to conduct this inspection.
In the event of a caisson not being vertical or in its correct position when it reaches the required depth, or in the event of a caisson being
structurally damaged (e.g. cracked) during sinking, the Contractor shall at his own cost carry out all necessary remedial work to the satisfaction
of the Engineer.
d) Data
The Contractor shall provide the Engineer with a complete record of types of material excavated during sinking, together with the level at which
each type of the material was found. In addition, a log showing rate-of-sinking shall be kept by the Contractor and furnished to the Engineer.
e) Filling the caissons
i) Concrete seal
The seal shall be constructed of mass concrete of class specified and shall be placed in accordance with dimensions and levels
shown on the drawings or as prescribed by the Engineer.
If this seal cannot be placed in the dry and must be placed under water, method of placing this concrete shall be approved by the
Engineer. The Contractor shall cease placing concrete under water when sufficient concrete was placed to seal the foundation
effectively.
After the concrete has been placed, the concrete seal and head of water over it shall remain undisturbed for a period of at least 7
days after which the caisson shall be dewatered by pumping for inspection. If more water is still leaking into the caisson, the
process of sealing as specified herein shall be continued until water level within the caisson rises at a rate < 10 mm/ hour.
The relevant requirements of Section A13.4 and Chapter 12 shall apply for placing concrete under water. For concrete placed
under water by methods other than tremie, cement content shall be 20 % more than the quantity required for ordinary concrete of
the same mix but > 450 kg per m3 of concrete.
ii) Filling
Subsequent to inspection of caisson compartments above the concrete seal, the compartments shall be filled with sand. The sand
shall be sufficiently wetted to obviate bulking.
The first 2,0 m of filling above the concrete seal shall be lowered gently into position. The sand may then be poured from the top
and compacted sufficiently to prevent settlement while the cover slab concrete is placed.
Top of sand fill within the caisson shall be finished to level specified below underside of caisson cover slab.
f) Stripping
Where walls of the caisson are overbuilt, concrete shall be stripped to required level without damage to concrete below cut-off level. Vertical
reinforcement of caisson shall protect above cut-off level by a distance greater than 50 times the bar diameter.
g) Concrete blinding below the caisson cover slabs
Concrete blinding of specified thickness and class shall be provided to the level shown on drawings over the area of the cover slab, including the
area within caissons on top of sand filling, except where the underside of the cover slab is formed with formwork.
A13.1.8 WORKMANSHIP
At commencement of construction the Contractor shall provide detailed process quality assurance procedures with regards to backfill, foundation
fill and grouting
A13.1.8.1 Definitions
Except where otherwise specified, the following aspects of construction, to which tolerances apply, shall have meanings attributed to them as
detailed below:
Position - the position of a structure or structural member shall be the horizontal position of its centre line(s) or centre point(s) in relation
to the overall layout of the works as shown on the drawings.

Alignment - alignment of a structure or structural member shall be the alignment of its centre line(s) in relation to the overall layout of the works
as shown on the drawings. Deviation from true alignment shall be measured in degrees of an arc.
Leading and cross-sectional dimensions - the leading and cross-sectional dimensions of a structure or structural member shall be
dimensions relating to width, length, height, thickness, etc., which collectively determine its shape, and are shown on the drawings. Dimensional
tolerances not relating to leading or cross-sectional dimensions shall be shown on the drawings.
Levels - the level of any structure or structural member shall be the level of the upper or lower surface, as may be relevant, with reference to an
established datum-level on the site.
Surface regularity - is the shape of a surface with reference to a 3,0 m straight-edge (or template in the case of curved surfaces) placed on this
surface. The tolerance for surface regularity is expressed as a distance by which the surface tested may deviate from a straight-edge (or
template in the case of curved surfaces) held against this surface.
For the assessment of acceptance and compliance the tolerances given below shall be the maximum permissible deviations from the
specified dimensions, levels, alignment, positions, etc., shown on drawings of the structures or structural members.
a) Foundations
Caissons:
Position of top of caisson ............................................................... 10 % of smallest outer dimension of caisson, measured in plan.
Verticality....................................................................................................................................................................................... 1,5°
Dimensions:
Wall thickness ........................................................................................................................................................ + 25 mm – 5,0 mm
Outer dimension of circular, rectangular or square cross-section ............................................................................................ ± 25 mm
Level: Upper level of trimmed/cut caisson head:
Maximum deviation of average level ....................................................................................................................................... ± 25 mm
Maximum deviation of any individual level .............................................................................................................................. ± 50 mm
Foundation fill:
Average level of top of foundation fill ...................................................................................................................................... ± 25 mm
b) Footings, pile capping slabs, caisson cover slabs, etc.
Position ..................................................................................................................................................................................... 15 mm
Alignment:
Alignment of individual member ........................................................................................................................................................ 5°
Alignment of members as they collectively determine
alignment of structure as a whole ........................................................................................................................................... 1 minute
Dimensions: Leading dimension in plan ................................................................................................................................. ± 25 mm
Thickness ................................................................................................................................................................ + 25 mm – 15 mm
Levels: Average level of slabs, footings, etc............................................................................................................................ ± 25 mm

B13.1 FOUNDATIONS
CONTENTS
B13.1.1 SCOPE
B13.1.2 DEFINITIONS
B13.1.3 GENERAL
B13.1.5 MATERIALS
B13.1.8 WORKMANSHIP
B13.1.1 SCOPE
This Section covers foundation and foundation related work and relates to the additional specification Clauses for the labour enhanced
excavation and backfilling of foundations.
B13.1.2 DEFINITIONS
Definitions as provided in A13.1.2 shall apply.
B13.1.3 GENERAL
Any activity specified in Part A, where hand work is envisaged, shall be executed in such a way as to maximise labour enhancement.

B13.1.5 MATERIALS

The Contractor shall before construction commences, provide comprehensive details of all plant and equipment, which shall be appropriate for
intended use. It shall be clear from the information provided that the required production rates and activities as indicated in the approved
construction program can be achieved.
Plant allowed for the labour enhanced construction work is limited to the following items:
• All and any compaction equipment/ plant.
• Water bowser for compaction water.
• Excavation plant may be used for excavations under water. All excavations in the dry shall be done using labour.
• Air compressors and hand-held breakers for excavating in intermediate excavation.
• Drilling equipment
• Dumpers, flat-bed trucks, tractor-trailer combinations or animal-drawn trailers

B13.1.7.1 Access and drainage
Not suitable for labour intensive work.
B13.1.7.2 Excavation
a) General
The labour enhanced work shall include excavations not provided for elsewhere in these specifications, which are required for founding the
structures as well as for excavating required in respect of demolition, extension or modification of existing bridges and culverts.
Excavation in the vicinity of existing structures and road formations shall be performed with due care and diligence. The Contractor shall take
special care not to disturb the founding material of any existing foundations and road formations. The excavation profile must strictly be as
approved by the Engineer and as shown on drawings.
Transportation of all materials shall be done with wheelbarrows up to the haul distance of 50 m. For haulage that is longer than 50 m,
transportation for the full distance shall be done by hand-loaded dumpers, flat-bed trucks, tractor-trailer combinations or by other approved
means.
b) Agreed excavation surface level and profiles
The provisions of Clause A13.1.7.2b) shall apply.
c) Excavation
All excavations in the dry shall be done by using labour. Excavations under water shall be undertaken with suitable plant.
In stable or hard material the Engineer may approve that the excavated surfaces can act as forms for casting of the concrete and the
excavations shall then be carried out and trimmed to neat dimensions of the concrete members shown on the drawings. To prevent moisture
loss in the concrete where excavated surfaces act as forms, a foundation lining shall be installed as specified in Clause A13.1.7.9. As an
alternative, provided that sufficient space is made available during excavation, an additional 50 mm of concrete cover, over and above that
specified may also be provided if approved by the Engineer. Excavations in soft material in excess of the authorised dimensions (over-
excavation) or overbreak in hard material shall be backfilled with the same class of concrete as that in the base.
In the case where excavations are made to neat dimensions of the concrete members (no formwork), compensation for the backfill of over-
break in hard material shall be measured and paid for under pay item C13.1.9 but the cost of backfilling of over-excavation in soft material shall
be at the Contractor’s own expense. Where additional excavation width is required for the erection of formwork, no additional compensation for
over-excavation or overbreak will be made except as provided for the applicable payment items.
The labour enhanced Contractor is not permitted to undertake blasting. Where blasting is required, the Contractor shall complete the entire
foundation excavation before commencing with the construction of any permanent concrete work, unless otherwise approved by the Engineer.
Boulders, logs or any other unsuitable material excavated shall be spoiled.
When material suitable for founding is encountered at the founding level, it shall be cut and trimmed to a firm surface, either level, stepped or
serrated, as may be required.
Where, in the opinion of the Engineer, unsuitable material is encountered at founding level, such material shall be removed and replaced with
foundation fill in accordance with Clause A13.1.7.6 and as directed by the Engineer.
d) Labour Enhancement Classification of Excavated Material
The Engineer shall classify excavated materials as soft or intermediate.
The Contractor shall notify the Engineer of the presence of what he considers to be rock or intermediate material immediately upon discovery
thereof. The Engineer will inspect the material and decide whether the material shall indeed be classified as suggested by the Contractor or not.
The decision of the Engineer shall be final and binding, subject to the provisions of the Contract.
(i) Intermediate
Intermediate excavation shall include rock banks breakable by conventional means (jack hammers using pneumatic or hydraulic
means), and in situ materials containing more than 40 % of any material (by volume) consisting of boulders each not exceeding
0,03 m3 in size.
(ii) Soft
Soft excavation shall be excavation in normal soft and hard soil containing less than 40 % (by volume) boulders each not
exceeding 0,03 m3.
(iii) Blasting
Blasting will not be permitted.
B13.1.7.3 Founding
All specifications under this sub-heading in the various sections of Clause A13.1.7.3, shall apply.
B13.1.7.4 Utilisation of excavated material

To the provisions of Clause A13.1.7.4 add the following:
The haul distance on excavated material and imported material for backfill shall be 100 m.

B13.1.7.5 to B13.1.7.9
All specifications under Clauses A13.1.7.5 to A13.1.7.9, shall apply.
B13.1.7.10 Caissons
Not suitable for labour intensive work.
B13.1.8 WORKMANSHIP

C13.1 FOUNDATIONS
(i) Preamble
plant, equipment, labour, tools, incidentals and supervision to carry out the activity or construct the works in the item, unless otherwise stated.
3. Wherever volumetric measurement is required, the volume will be computed from the depth determined as indicated in 1. above and using the
4. Where shoring is specified or ordered, the length of shoring measured for payment will be the length of the centre-line of the open drain or
trench.
5. Payment in accordance with item C13.1.9 for the construction of fill within restricted areas shall be made only when specifically provided for in
the schedule of quantities otherwise it shall be deemed to be included in the other tendered rates.
pay items.
6. No separate payment will be made for the hauling of any materials where the material is moved over a distance of less than, and up to 1,0 km
and for labour enhanced construction, less than and up to 50 m.
For activities in Table C13.1-1 pay items specified in other Chapters or Sections of the specifications, where they relate to work under this
C5.2.2 of Chapter 5 - All applicable
Fill within a restricted are C13.1.9
items
C13.1.3, C13.1.4, C13.1.7.2, Section C1.7 of Chapter 1 – All
C13.1.8.2, C13.1.10, C13.1.11, applicable items
Hauling materials C13.1.14.1, C13.1.14.2, C13.1.14.3,
C13.1.15.1, C13.1.15.2, C13.1.15.3,
C13.1.30 and C13.1.31
Chapter 4 – All applicable items
Mass earthworks C13.1.23


C13.1.1 Provision of designs and drawings of temporary works by an ECSA-registered lump sum
Professional Engineer or Technologist or Geotechnical Engineer (description of works
to which applicable):
The unit of measurement shall be the lump sum and shall be paid in two payments; 50% on submission of the temporary work designs and the
second 50 % on complete removal of all the temporary works.
The tendered rates shall include full compensation for procuring and provision of all drawings of the temporary works, designs by an ECSA-
registered Professional Engineer or Technologist or Geotechnical Engineer, including all labour, material, travelling and incidentals, time delays
and submission of all the certificates as specified.
C13.1.2 Additional foundation investigations:
C13.1.2.1 Provisional sum allowed for additional foundation investigations provisional sum
The provisional sum allowed under subitem (a) shall only be expended on submission of actual costs of the appointed sub-Contractor for the
additional foundation investigation.
The tendered percentage of subitem (b) is a percentage of the amount actually spent under subitem (a) and shall include full compensation for
all charges and incidental costs of the Contractor, profit and overheads.
C13.1.3 Excavation:
C13.1.3.1 Excavating soft material situated within the following successive depth ranges:
(a) 0 m up to 1,5 m cubic metre (m3)
(b) > 1,5 m and < 3,0 m cubic metre (m3)
(c) Etc. in increments of 1,5 m cubic metre (m3)
C13.1.3.2 Extra over subitem C13.1.3.1 for excavation in hard material irrespective of depth cubic metre (m3)
C13.1.3.3 Extra over subitem C13.1.3.1 for additional excavation required by the Engineer after cubic metre (m3)
excavation is complete
C13.1.3.4 Extra over subitem C13.1.3.1 for excavation by hand cubic metre (m3)
C13.1.3.5 Extra over subitem C13.1.3.1 for excavation in restricted areas cubic metre (m3)

C13.1.4 Excavation by labour enhanced methods:
C13.1.4.1 Excavate in soft material situated within the following successive depth ranges:
C13.1.4.2 Extra over item C13.1.3.1(a) for excavation in intermediate material cubic metre (m³)
C13.1.4.3 Extra over item C13.1.3.1(a) for additional excavation required by the Engineer after cubic metre (m³)
excavation is complete
Limits for successive depth ranges shall be measured vertically down from surface levels agreed (Clause A13.1.7.2b)) to founding level (Clause
A13.1.7.3) agreed.
In the case of excavations required for diverting, channelization or widening streams, successive depth ranges for those portions of excavations
that are within 5,0 m of a concrete structure shall be measured from surface levels agreed to invert level of channel or stream.
Unit of measurement shall be the cubic metre of material, measured in original position before excavation. Quantity of excavation for each depth
range shall be calculated from neat outlines of base or floor and depth of excavation completed within each range.
Excavation required for diverting, channelling or widening streams within 5,0 m of concrete structures shall be measured and paid for under item
C13.1.3. Excavations beyond this 5,0 m limit shall be measured and paid under the appropriate items in Chapters 3 and 4 unless otherwise
provided for in the Contract Documentation.

To provide working space for erecting formwork, the extremities of the excavation, for purposes of measurement and payment, shall be deemed
to be the vertical planes parallel to and 0,5 m outside the perimeter of concrete members for which formwork is provided.
Irrespective of the total depth of excavation, the quantity of material within each depth range shall be measured and paid for separately.
Supplementary payment for the excavation by hand as specified in Clause C13.1.3.4 shall constitute full compensation for incidentals for hand-
excavating materials instead of using mass-excavating equipment.
Where foundation fill is constructed in an excavation, the quantity of excavated material measured for payment shall be material excavated
between average ground level, as described in Clause A13.1.7.2b), and founding level, from a prism with vertical sides, as described in Clause
A13.1.7.6 or as prescribed by the Engineer.
In no case shall any of the following excavations be included in the measurement for payment:
(i) The volume of excavation in excess of above-mentioned limits.
(ii) The volume included within the excavated road prism, contiguous channels, ditches, etc, for which payment is provided elsewhere in
the specifications.
The tendered rates shall include full compensation for excavation in each class of material, the spoiling or stockpiling of material, the hauling of
excavated material for a haul distance of 1,0 km and in the case of labour enhanced methods a haul distance of 50 m, any additional excavation
the Contractor may require for additional working space outside the authorised limits, trimming and cleaning the bottoms and sides of
excavations, and safeguarding the excavations. Payment for strutting and shoring the excavations shall be paid under a separate item.
If, after a foundation excavation has been completed, cleaned and trimmed ready for concrete screeding, the Engineer orders further
excavations to be made on account of changed dimensions or founding conditions, an extra over payment (item C13.1.3.3 on the additional
excavation measured for payment shall be payable in full compensation for any incidentals to the Contractor over and above the normal
excavation costs.
C13.1.5 Mass excavation within a restricted area (extra over item C13.1.3) cubic metre (m³)
Unit of measurement shall be the cubic metre and quantities shall be taken as total volume of material within the restricted area as defined in
Clause A13.1.7.5. The quantity shall not include volume of excavation which is measured and paid for under item C13.1.3 above.
Tendered rate shall include full compensation for all additional work necessitated by working in restricted areas.
C13.1.6 Access and drainage:
C13.1.6.1 Access lump sum

The tendered lump sum shall include full compensation for providing access, which, inter alia, shall include constructing temporary banks,
artificial islands or cofferdams, their protection, safeguarding and maintenance as well as any incidentals in respect of work below standing
water.
75 % of the lump sum will be paid when the access is constructed. The remaining 25 % will be paid after the access has been removed.
Payment for draining of excavations shall be made separately under item C13.1.6.2.
C13.1.6.2 Drainage lump sum

Payment will be made for this work by way of a lump sum for each structure or series of structures appearing separately in the schedule of
quantities. The lump sum shall be paid on a pro rata basis as the work progresses.
The tendered lump sum shall include full compensation for draining by pumping or in any other way and for any other work necessary for
keeping the excavations dry or for working in the dry.
Where dewatering and keeping dry of excavations is not billed separately as per this item C13.1.6.2 it shall be deemed to be included in rates
tendered and paid for excavation and backfill.
C13.1.7 Backfill to excavations utilising:
C13.1.7.1 Material from excavation cubic metre (m3)
C13.1.7.2 Imported material cubic metre (m3)
C13.1.7.3 Soil cement cubic metre (m3)
C13.1.8 Backfill to excavations utilising labour:
C13.1.8.1 Material from excavation cubic metre (m³)
C13.1.8.2 Imported material cubic metre (m³)

C13.1.8.3 Soil cement cubic metre (m³)
The unit of measurement shall be the cubic metre of backfill material measured in the excavation. The quantity measured shall be calculated
from within the neat outlines defined for excavation under item C13.1.3 and height to which the backfilling is constructed. The volume occupied
by the structure shall be subtracted when calculating volume of backfilling.
The height shall be determined by the upper surface of the road prism or reference ground surface (Clause A13.1.7.2b)), whichever is the lower.
The tendered rates shall include full compensation for furnishing and placing all materials within the entire excavation, transporting the material
within haul distance of 1,0 km, and in the case of labour enhanced methods a haul distance of 100 m, and preparing, processing, shaping,
watering, mixing and compacting the material to the specified densities.
C13.1.9 Fill within a restricted area (extra over item C5.2.2) cubic metre (m3)
The unit of measurement shall be the cubic metre and the quantity shall be taken as total volume of material within the restricted area as defined
in Clause A13.1.7.5 d). This quantity shall not include the volume of backfill measured and paid for under items C13.1.7 and C13.1.8.
The tendered rate shall include full compensation for all additional work necessitated by working in restricted areas and for increased density
required in restricted areas.

C13.1.10 Haul in excess of 1,0 km on excavated material and on material imported for backfill, cubic metre-kilometre
foundation fill and fill for caissons (m3-km)

C13.1.11 Haul in excess of 50 metres on excavated material and on foundation fill for labour cubic metre-kilometre
enhanced construction (m3-km)
Haul shall be measured and paid for as specified in Section C1.7 of Chapter 1 and shall apply only to that portion of the material qualifying for
payment under items C13.1.3, C13.1.4, C13.1.7.2, C13.1.8.2, C13.1.10, C13.1.11, C13.1.14.1, C13.1.14.2, C13.1.14.3, C13.1.15.1, C13.1.15.2,
C13.1.15.3, C13.1.30 & C13.1.31
Haul shall not apply to concrete used in foundation fill.
C13.1.12 Overbreak in excavation in hard material: square metre (m2)

C13.1.13 Overbreak in excavation in hard material for labour enhanced construction: square metre (m2)
The unit of measurement shall be the square metre of surface area of the vertical outer faces of the base where excavations are made to “neat”
dimensions of the base.
The tendered rate shall include full compensation for the overbreak material removed from the excavation in hard material, for the concrete fill in
accordance with Clause A13.1.7.6, and any additional screeding concrete required.
C13.1.14 Foundation fill consisting of:
C13.1.14.2 Crushed-stone fill cubic metre (m3)
C13.1.14.3 Compacted granular material cubic metre (m3)
C13.1.14.4 Mass concrete (class indicated) cubic metre (m3)
C13.1.14.5 Concrete blinding (thickness and class of concrete indicated) cubic metre (m3)
C13.1.14.6 Plum concrete (class indicated) cubic metre (m3)

C13.1.15 Foundation fill placed by labour enhanced methods consisting of:
C13.1.15.2 Crushed-stone fill cubic metre (m3)

C13.1.15.3 Compacted granular material cubic metre (m3)
C13.1.15.4 Mass concrete (class indicated) cubic metre (m3)
C13.1.15.5 Concrete blinding (thickness and class of concrete indicated) cubic metre (m³)
C13.1.15.6 Plum concrete (class indicated) cubic metre (m³)
The unit of measurement shall be the cubic metre of approved material placed and compacted below the bases as specified or where directed
by the Engineer.
The quantity of foundation fill to be measured for payment shall be the material contained within the prism specified in Clause A13.1.7.6 or shall
otherwise be the quantity to the outlines shown on the drawings or as directed by the Engineer.
The tendered rates shall include full compensation for procuring, furnishing, transporting for a haul distance of 1,0 km (subitems (a) to (c) only),
placing and compacting material and in the case of labour enhanced methods, a haul distance of 50 m.
C13.1.16 Establishment on site for drilling of holes and grouting of rock fissures (type of drilling lump sum
indicated):
The tendered lump sum shall include full compensation for establishment on the site and the subsequent removal of all special equipment and
plant for drilling the holes, grouting of rock fissures and any additional plant for carrying out operations, the cost of which does not vary with the
actual amount of work to be done.
This work will be paid for by way of a lump sum, 75 % of which will become payable when all equipment is on the site and the first hole has been
grouted. The remaining 25 % will become payable after all holes have been grouted and equipment removed from site.
C13.1.17 Moving to and setting up equipment at each hole to be drilled for grouting: number (No)
The unit of measurement shall be number of positions to which the equipment has to be moved and set up for drilling and grouting rock fissures.
The number to be measured shall equal number of holes drilled as instructed by the Engineer.
Tendered rate shall include full compensation for all the costs involved in moving and setting up the equipment.
C13.1.18 Drilling of holes for grouting (diameter and type of drilling indicated): metre (m)
The unit of measurement shall be the metre of hole drilled.
The tendered rate shall include full compensation for drilling and clearing the holes as specified.
C13.1.19 Grouting of rock fissures (type of grout and for which purpose it is required indicated): kilogram (kg)
The unit measurement for grouting shall be the kilogram of cementious binder or proprietary grout as may be applicable used in the grouting
operation.
The tendered rates shall include full compensation for providing the equipment and all material and mixing and pumping the grout into the
prepared holes in accordance with instructions of the Engineer, and also for the water-pressure tests.
C13.1.20 Dowel bars:
C13.1.20.1 Drilling and preparation of holes (diameter and length indicated) metre (m)
C13.1.20.2 Supply and installation of dowel bars
(type, diameter, length, corrosion protection, together with type of grout, indicated) kilogram (kg)
The unit of measurement for drilling and preparation of holes in rock shall be the metre of holes drilled while unit of measurement for dowel bars
shall be the kilogram of bars provided and secured in position.
The tendered rates shall include full compensation for drilling holes, preparing holes for grouting i.e. saturating and cleaning, supplying all the
material and positioning and grouting the dowel bars as specified.
C13.1.21 Foundation lining (type of material and thickness indicated): square metre (m2)
The unit of measurement for foundation lining shall be the square metre of concrete surface lined.
The tendered rates shall include full compensation for procuring, furnishing and placing all material and incidentals required for completing the
work as specified.

C13.1.22 Foundation lining (type of material and thickness indicated), using labour enhanced square metre (m2)
methods
The unit of measurement for foundation lining shall be the square metre of concrete surface lined.
The tendered rates shall include full compensation for procuring, furnishing and placing all material, labour and incidentals required for
completing the work as specified.
C13.1.23 Lateral support for excavations:
C13.1.23.1 Excavation or fill at (indicate location)
(a) 0 to 2,5 m depth square metre (m2)
(b) 2,5 to 5,0 m depth square metre (m2)
(c) Etc. at other locations

The unit of measurement shall be the square metre of lateral support at a specific location over successive depth ranges. Depth ranges shall be
measured down from the level where lateral support is required at each location and agreed with the Engineer.
The rates shall include full compensation for design, supply, fabrication, installation, removal (if required), labour, materials, equipment, plant
and incidentals to provide complete lateral support to the excavated or filled faces. The rate shall also include inspections, supervision by safety
officer and for maintenance of lateral support. The lateral support shall remain in position as long as required to complete construction and only
removed with the approval of the Engineer. Where lateral support for excavations are required, cost for excavating material shall not be
included, but paid for under items C13.1.3 or the appropriate mass earthworks items under Chapter 4.
Where lateral is not billed separately as per this item C13.1.23 it shall be deemed to be included in rates tendered and paid for excavation and
backfill.
C13.1.24 Establishment on site for constructing caissons lump sum

The tendered lump sum shall include full compensation for the establishment on site and later removing all special plant and equipment
necessary for constructing the caissons. This cost shall not vary with number of caissons constructed.
This work will be paid for by way of lump sum, 50 % of which will be paid when all the equipment is on the site and the first caisson is
constructed. The second 25 % will be paid after half the caissons are completed, and the final instalment of 25 % after all caissons are complete
and equipment is removed from site.
C13.1.25 Formwork for caissons (class of finish indicated) square metre (m2)
The unit of measurement shall be square metre of formwork, and only area of formwork in contact with finished faces of concrete shall be
measured. Formwork for construction joints shall be measured for payment under class F1 surface finish but shall be measured only for the
construction joints shown on drawings or as prescribed by the Engineer.
The tendered rate shall include full compensation for supplying all materials, erecting falsework and formwork, constructing forms, forming
grooves, fillets, chamfers, stop ends for construction joints, treating forms, all accessories, and stripping and removing the formwork after
completion of the work. Payment for the formwork shall be made only after the formwork is stripped and surface finish approved.
C13.1.26 Steel reinforcement for caissons:
C13.1.26.1 Mild-steel bars ton (t)
C13.1.26.2 High-yield-stress-steel bars (type indicated) ton (t)

The unit of measurement for steel bars shall be the ton of reinforcement in place in accordance with drawings or as authorised.
Ties and other steel used for positioning reinforcing steel shall be measured as steel reinforcing under the appropriate subitem.
The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding, trial welding joints, placing and fixing
steel, including all tying wire, spacers and waste.
C13.1.27 Cast in situ concrete in caissons and concrete seals (class of concrete indicated) cubic metre (m3)
The unit of measurement for cast in situ concrete shall be the cubic metre of concrete in place. Concrete quantities in caissons shall be
calculated from dimensions shown on drawings or authorised by the Engineer, and length of caisson from founding level to specified cut-off

level. Quantity of concrete in the concrete seal shall be calculated in accordance with dimensions shown on drawings or authorised by the
Engineer.
The tendered rate shall include full compensation for procuring and furnishing all materials, storing material, providing all plant, mixing,
transporting, placing and compacting concrete, all sealing, curing of concrete and repairing defective concrete. Payment shall distinguish
between the different classes of concrete.
C13.1.28 Cutting edge for (diameter/ size indicated) caissons number (No)
The unit of measurement shall be number of caissons provided with cutting edges, irrespective of constructed material.
The tendered rate shall include full compensation for manufacturing, supplying, delivering and installing the complete cutting edge as well as for
joining cutting edge to caisson unit. Where cutting edge is of concrete and forms part of the bottom element, tendered rates shall include full
compensation for all additional work required for completing the element.

C13.1.29 Sinking (diameter/size indicated) caissons through material situated within the
following successive depth ranges:
C13.1.29.1 0 m up to 5,0 m metre (m)
C13.1.29.2 Exceeding 5,0 m and up to 10 m metre (m)
C13.1.29.3 Etc.in increments of 5,0 m depths metre (m)

Limits of successive depth ranges shall be measured down from the firm horizontal base (Clause A13.1.7.10b)) to agreed founding level (Clause
A13.1.7.3).
The unit of measurement shall be the metre of caisson sunk.
Irrespective of length of caisson sunk, quantity for each depth range shall be measured and paid for separately.
The tendered rates shall include full compensation for locating and holding in position, dewatering, pumping, kentledge and lubricating sides of
the caisson, and for all work in connection with sinking the caisson which is not paid for elsewhere.
C13.1.30 Excavation for caissons:
C13.1.30.1 Excavating soft material situated within the following successive depth ranges:
(c) Etc in increments of 2,0 m depths cubic metre (m3)
C13.1.30.2 Extra over subitem C13.1.24.1 for excavation in hard material irrespective of depth cubic metre (m3)
Limits for successive depth ranges shall be measured from the firm horizontal base (Clause A13.1.7.10b)) to excavated level inside the caisson.
The unit of measurement shall be the cubic metre of material, measured in original position before excavation. Quantity of excavation for each
depth range shall be calculated from the gross area of caisson in plan and depth of excavation completed within each depth range.
Irrespective of total depth of excavation, quantity of material within each depth range shall be measured and paid for separately.
The tendered rates shall include full compensation for excavation in the classified material, spoiling or stockpiling material, hauling excavated
material for haul distance of 1,0 km, trimming bottom of excavation, dewatering, pumping and removing material leaking into the caisson before
sealing.
C13.1.31 Filling the caissons cubic metre (m3)

The unit of measurement shall be the cubic metre of sand placed above the concrete seal in the caisson compartments.
The tendered rate shall include full compensation for supplying and placing sand, transporting material within a haul distance of 1,0 km, and
compacting material as specified.
C13.1.32 Stripping (size of caisson indicated) caisson heads number (No)

The unit of measurement shall be number of caissons of each size stripped.
The tendered rate shall include full compensation for cutting away, trimming and disposing of concrete removed at an approved dump site.

D13.1 FOUNDATIONS
CONTENTS
D13.1.1 SCOPE
D13.1.2 GENERAL

13.2 FALSEWORK, FORMWORK AND CONCRETE FINISH
CONTENTS
A13.2.1 SCOPE
A13.2.2 DEFINITIONS
A13.2.3 GENERAL
A13.2.5 MATERIALS
A13.2.8 WORKMANSHIP

A13.2 FALSEWORK, FORMWORK AND CONCRETE FINISH

A13.2.1 SCOPE
This Section covers the design, supply and erection of all falsework and formwork used in the construction of permanent work.
This Section also describes the classes of surface finishes on formed and unformed concrete surfaces.
A13.2.2 DEFINITIONS
Falsework - is any temporary construction used to support the loads for a structure until it becomes self-supporting.
Formwork - is the temporary structure, mould or form used to retain plastic or fluid concrete in its designated shape until it hardens.
Formed Surfaces - there are 3 classes of struck off the form surface finishes.
Unformed Surfaces - there are 3 classes of surface finish.
A13.2.2.1 Formwork to exposed surfaces

a) Formwork to faces of structures with a gradient equal to or greater than five vertical to one horizontal shall be classified as vertical
formwork.
b) Formwork to faces of structures where the gradient is less than one vertical to five horizontal shall be classified as horizontal formwork.
c) Formwork to faces of structures is outside the limits of vertical or horizontal formwork shall be classified as inclined formwork.

Except where otherwise specified, the following aspects of construction to which tolerances apply shall have the meanings attributed to them
below:
a) Position
The position of a structure or structural member shall be the horizontal position of its centre line (s) and/or centre point(s) in relation to the
overall layout of the works as shown on the drawings.
b) Alignment
The alignment of a structure or structural member shall be the alignment of its centre line(s) in relation to the overall layout of the works as
shown on the drawings. Deviation from true alignment shall be measured in degrees of an arc.
c) Leading and cross-sectional dimensions
The leading and cross-sectional dimensions of a structure or structural member shall be the dimensions relating to width, length, height,
thickness, etc, which collectively determine its shape, and are shown on the drawings. Dimensional tolerances not relating to leading or cross-
sectional dimensions shall be shown on the drawings.

d) Levels
The level of any structure or structural member shall be the level of the upper or lower surface, as may be relevant or defined, with reference to
an established datum-level on the site.
e) Surface regularity
Surface regularity is the shape of a surface with reference to a 3,0 m straight-edge (or template in the case of curved surface) placed on the
surface.
The tolerance for surface regularity is expressed as a distance by which the surface tested may deviate from a straight-edge (or template in the
case of curved surfaces) held against the surface.
A13.2.2.3 Sliding formwork

Vertical slip forming concrete consists of a concrete form which may be surrounded by a platform for workers to stand, place the steel
reinforcement into the concrete and ensure smooth casting. The formwork is raised by hydraulically jacks at a rate which permits the concrete to
set by the time it emerges from the bottom of the form.
A13.2.2.4 Contractors design

The Contractors design is the design of the falsework and formwork carried out by a competent person who is a Professional Engineer or
technologist registered with ECSA with appropriate experience.
A13.2.3 GENERAL
Notwithstanding approval given by the Engineer for the design and drawings prepared by the Contractor for the falsework and formwork and the
acceptance of the falsework and formwork as constructed, the Contractor shall be solely responsible for the safety and adequacy of the
falsework and formwork and shall indemnify and keep indemnified the Employer and Engineer against any losses, claims or damage to persons
or property whatsoever which may arise out of or in consequence of the design, construction, use and maintenance of the falsework and
formwork and against all claims, demands, proceedings, damages, costs, charges and expenses and risks whatsoever in respect thereof or in
relation thereto.
For works on, over, under or adjacent to any railway line, walkway, existing road or any other facility which is controlled by a statutory authority,
the Contractor shall comply, inter alia, with the requirements for the preparation and submission of drawings for falsework and formwork, and the
submission of certificates for the proper construction thereof, all in accordance with the official specifications of such authority.
After having constructed the falsework and formwork, and prior to placing the reinforcing steel and/or the concrete, the Contractor shall inspect
the falsework and formwork. Dimensions shall be checked, unevenness of surface shall be corrected, and special attention paid to the
adequacy and tightness of all bolts, ties and bracings as well as to the soundness of the foundations.
The Contractor shall give the Engineer at least 24 hours' notice of his intention to place the concrete to enable the Engineer to inspect all
aspects of the completed work. However, before notifying the Engineer, the Contractor shall satisfy himself that the work complies in all
respects with the specifications.
Concrete sections with dimension of smaller than 200 mm shall not be formed with sliding formwork unless authorised by the Engineer.
Where no provision has been made in the schedule of quantities for sliding formwork, the Contractor may, in a covering letter to the tender,
submit a lump sum which reflects a saving in the cost for the use of sliding formwork in lieu of conventional formwork. The tendered lump sum
quoted shall be accompanied by rates for pay items C13.2.7, C13.2.8, C13.2.9 and C13.3.3 all in accordance with the measurement and
payment Clauses. Such submission shall be regarded as an alternative tender for the purposes of tender evaluation, and shall in every respect
comply with the provisions of Clause A13.2.4.
The Contractor shall at all times during the supply and erection of falsework and formwork assure that safety standards and requirements as
prescribed in the Regulations are adhered to.

The method statements and typical drawings submitted by the Contractor with his tender submission, describing key facets such as method, key
plant, materials, personnel and programme constraints of the envisaged construction process, shall form the basis for the detailed method
statements required for the works to be executed on the project.
the Engineer.

A13.2.3.2 Hold points and approvals

A13.2.4.1 General
The Contractor's design and drawings of the falsework and formwork shall comply amongst others with all statutory requirements.
The Contractors design of all falsework and formwork shall be carried out by an ECSA Registered Professional Engineer or Technologist with
relevant experience and shall be carried out in accordance with, but not limited to the TMH7 loading as amended from time to time. The
drawings and calculations shall be submitted to the Engineer for approval at least 14 days prior to the commencement of the work, in an
appropriate format as required by the Engineer.
The Contractor shall submit to the Engineer at least 28 days before the structure is scheduled for construction a detailed analysis showing the
effect of the stresses that will be induced by the Contractor’s chosen method of construction. The cost of any additional prestressing, reinforcing
steel, concrete, etc, required as a result of the Contractor’s chosen method of construction shall be to the Contractor’s account. No construction
shall commence until the Engineer has given his written approval.
The Contractors registered professional shall also sign off on the erection of the falsework and formwork after the erection thereof and submit to
Engineer before the Engineer will permit the work to proceed. All work shall be carried strictly in accordance with the Construction Regulations.
Unless specifically measured under item C13.2.10 the cost of the above shall be deemed to be included in the general rates tendered for
formwork.
A13.2.4.2 Falsework
The Contractor shall submit his design criteria and detailed drawings of the falsework to the Engineer. The design, signing of the drawings and
inspection of the falsework prior to construction of the permanent works shall be undertaken by the Contractor’s ECSA Registered Professional
Engineer or Technologist falsework designer.
The Contractor shall make his own assessment of the allowable bearing pressure on the foundation material and shall design the footings and
falsework to prevent overloading, differential settlement and unacceptable overall settlement and safety. In assessing the allowable bearing
pressure, due account shall be taken of the effect of wetting on the foundation material.
The Contractor’s falsework designer shall take account of the location of the structure and the possible ingress of water from sources such as
watercourses, water table and saturation due to rainfall and assess the resulting effects on bearing capacity
In designing the falsework, cognizance shall also be taken of the redistribution of load which may occur on account of the effect of temperature,
wind force, the prestressing of curved and skewed structures, stage construction, flooding and debris.
Cognizance shall also be taken of the lateral forces which may be induced by earth platforms, required for the support of falsework on the
substructures resulting in temporary or permanent stresses for which the sub-structures have not been designed.
Particular attention shall be given to providing transverse and diagonal bracing as well as rib stiffeners on cross bearers.
A13.2.4.3 Formwork
a) General
Formwork shall be so designed as to be sufficiently rigid to ensure that the specified dimensional tolerances can be achieved under the
combined action of self-weight, dead load and imposed loads as well as the additional loads resulting from the rate of concreting, the layer
thickness of the concrete cast in one operation and the method of placing and compaction.
b) Sliding formwork
The Contractor shall be responsible for the design of sliding formwork, if any is intended to be used. Prior to fabrication or bringing the sliding
formwork and any additional equipment to the site, the Contractor shall submit drawings of the complete sliding- formwork assembly to the
Engineer for approval. The drawings shall show full details of the forms, jacking frames, access ladders, hanging platforms, safety rails and
curing skirts as well as details of the jacks and jack layouts.
The Contractor shall be required to submit to the Engineer, before slide casting commences, an instruction manual in which the sliding
techniques, jacking procedure, methods of keeping the formwork level, the procedure to be adopted to prevent bonding of the concrete to the
forms and a method for releasing the forms in the event of bonding, the instrumentation and monitoring of the slide casting and correcting for
verticality, twisting and levelness are described in detail. The manual shall also include detail procedures for corrective actions to be
implemented in the event that any problem that might conceivably occur, actually manifests.
The formwork panels shall be inclined to give a small taper, the forms being slightly wider at the bottom than at the top.
The taper shall be so designed as to produce the specified concrete thickness at the mid-lift level of the form.
The spacing of the jacks with their jack rods shall be so designed that the dead load of the sliding-formwork assembly, the frictional load, and the
mass of materials, personnel and equipment will be evenly distributed and within the design capacity of the jacks used.

A13.2.5 MATERIALS
A13.2.5.1 General
The materials used in the construction of falsework (including its support system) and formwork shall be suitable for the purpose for which they
are required and be of such quality as to produce the specified standard of work. The type, grade and condition of the material shall be subject
to the Engineer's approval.
The use of in situ or imported stabilised soil as a support system shall only be permitted in special cases if approved by the Engineer.
A13.2.5.2 Falsework
The timber, structural steel and scaffolding used shall be free from defects that may prejudice the stability of the falsework. The jacks, devices,
clamps and fittings shall all be in a good working order and of adequate design and strength.
A13.2.5.3 Formwork
a) Tongue-and-groove boarding
Tongue-and-groove boarding shall be of suitably dried timber which will not warp, distort or cause discolouration of the concrete. The widths of
the boards shall be as specified on the drawings or in the schedule of quantities or as prescribed by the Engineer. Boards shall be supplied in
lengths not shorter than 3,0 m.
b) Steel forms to exposed surfaces
For classes F2 and F3 surface finish the individual panels shall be assembled sufficiently rigidly and so clamped as not to deform or kick during
handling or under the pressure of the wet concrete.
The surfaces of forms which are to be in contact with the concrete shall be clean, free from deposits or adhering matter, ridges or spatter which
will impart irregularities and blemishes to the concrete surface, and shall also be free from indentations and warps.
The thickness of the steel forms shall be adequate to support the forces applied by the wet concrete but shall not be less than 2,5 mm.
c) Void formers
Void formers used in permanent work shall be subject to the approval of the Engineer.
Where void formers of a special design are required, details thereof shall be specified.
Void formers shall always be tied down to the falsework using mild steel anchor ties with minimum characteristic yield strength of 250 MPa.
Void formers shall be manufactured from material which will not leak, tear or be damaged during the course of construction and shall be of such
tight construction as to prevent undue loss of the mortar component of the concrete through leakage. The units shall be sufficiently rigid so as
not to deform during handling or under the pressure of the wet concrete.
For mild-steel spiral-lock-formed void formers, the metal thickness, unless otherwise specified shall be as follows:
(i) Unbraced void formers
1,0 mm for diameters of up to 600 mm
(ii) Braced void formers
1,2 mm for diameters from 600 mm to 1 000 mm
1,6 mm for diameters exceeding 1 000 mm.
The thickness specified for braced void formers shall apply to formers internally braced with timber or equivalent braces. The
braces shall be at spacings not exceeding 1,5 m and not further than 1,0 m from the end of each unit. Timber cross braces shall
consist of members with cross sectional dimensions of at least 50 mm x 50 mm. The cross bracing shall be vertical and horizontal
and have longitudinal walers attached to ends of the bracing of the same cross sectional dimensions.
All hollow void-former units shall be provided with a 12 mm diameter drainage hole at each end.
d) Chamfer and recess fillets
Timber fillets used for forming chamfers and recesses on exposed surfaces shall be made from new suitable material unless otherwise
e) Jack rods for sliding formwork
The jack rods, base plates and couplers shall be strong enough to carry the design load under all operating conditions without buckling,
distorting or causing damage to the concrete. Jack rods which are to remain permanently embedded in the concrete shall comply with the
requirements of Clauses A13.3.7 and A13.3.8. Under no circumstances shall bent rods be used in the work.
The jack rods used shall have a diameter of at least 25 mm.

The Contractor shall before the construction commences, provide comprehensive details of all plant and equipment which shall be appropriate
for the construction and erection of falsework and formwork. All plant and equipment shall be in a good working condition for the purpose
suitable.

A13.2.7.1 Falsework
Falsework shall be erected in accordance with the approved drawings incorporating such modifications as required by the Engineer.
The Contractor shall take precautions to prevent deterioration of the foundations during the course of construction.
The falsework shall incorporate features which will permit adjustment to the alignment of the formwork to neutralise the unforeseen or expected
settlement and deflection under load, prior to commencement of concreting activities.
A13.2.7.2 Formwork
a) General
The formwork for concrete work including bridge decks shall be erected to levels calculated from the information given on the drawings for
roadworks and bridges. The levels shall be adapted to make provision for the specified precamber as well as for the expected deflection and
settlement of the fully loaded falsework and formwork. The levels shall be set out and checked at intervals not exceeding 2,50 m, to assure
compliance with specified construction tolerances of the completed work.
For constructing the formwork, the Contractor may, subject to the provisions of Clause A13.2.5, use any material suitable for and compatible
with the class of surface finish and dimensional tolerances specified for the particular member (unless specific type of formwork has been
prescribed in the Contract Documentation).
Formwork shall be sufficiently rigid to maintain the forms in their correct position, shape and profile and shall be of such tight construction that
the concrete can be placed and compacted without undue loss or leakage of the mortar component of the concrete.
The joints between contiguous formwork elements shall be of a tight fit and, where necessary, the joints shall be caulked, taped or packed with a
sealing gasket, all at no extra payment if undue leakage occurs or can be expected. Paper, cloth or similar material shall not be used for this
purpose.
The formwork construction shall permit accurate erection and easy stripping without shock, disturbance or damage to the cast concrete. Where
necessary, the formwork assembly shall permit the removal or release of side forms Independently of the soffit forms.
Metal supports, ties, hangers and accessories embedded in the concrete shall be removed to a depth of not less than the cover specified for the
reinforcement. No wire ties shall be used.
All external corners shall be chamfered by fillet strips being fixed into the corners of the formwork to form 25 mm x 25 mm chamfers, or such
other dimensions as may be specified on the drawings. Re-entrant angles need not be chamfered unless specified.
Where polystyrene or similar material, susceptible to damage is used, it shall be lined with a hard surface on the side to be concreted. The hard
material shall be sufficiently resilient to ensure that the required quality of work can be achieved.
Where it is specified, all formwork ties shall be provided with recoverable truncated cones between sleeve ends and formwork faces to ensure
that sleeve ends are not exposed on concrete surfaces. The cones shall have a minimum depth of 50 mm.
All ferule and tie holes shall be filled using a mortar compatible with the concrete in strength and colour.
The formwork and boards shall be so arranged as to form a uniform and regular pattern in line with and perpendicular to the main axis of the
member, unless otherwise approved or directed by the Engineer.
Joints between contiguous members shall, after caulking, taping or sealing, be treated to prevent blemishes, stains and undue marks from being
imparted to the concrete surface.
Bolt and tie positions shall be neatly arranged so that they conform to the symmetry of the formwork panels or boards. Bolt and rivet heads
which will be in contact with the formed surface shall be of the countersunk type and shall be treated to prevent marks from forming on the
concrete surface.
The formwork at construction joints shall be braced to prevent steps from forming in the concrete surfaces at the joints between successive
stages of construction.
The formwork at construction joints shall have moulding strips 25 mm x 25 mm neatly butted and set at the position of the construction joint.
Where moulding or recess strips are specified, they shall be neatly butted or mitred.
(i) Protecting the surfaces
The Contractor shall ensure that permanently exposed concrete surfaces are protected from rust marks, spillage and stains of all
kinds and other damage during construction.
b) Formed surfaces: Classes of finish
(i) General
In addition to complying with the tolerances specified in Clause A13.2.8, the surface finish on formed concrete surfaces shall also
comply with the following requirements:
1. Class F1 surface finish
After repair work has been done to surface defects in accordance with Clause A13.2.7.4, no further treatment of the as-stripped finish will
be required. This finish is required on concealed formed surfaces.
This finish shall be equivalent to that obtained from the use of square-edged timber panels and boards wrought to the correct thickness, or
shutter boards or steel forms arranged in a regular pattern. This finish is intended to be left as struck but surface defects shall be remedied
in accordance with Clause A13.2.7.4. Although minor surface blemishes and slight discolourations will be permitted, large blemishes and

severe stains and discolouration shall be repaired where so directed by the Engineer.
This finish shall be that obtained by first producing a class F2 surface finish with joint marks which form an approved regular pattern to fit in
with the appearance of the structure. All projections shall then be removed, irregularities repaired and the surface rubbed or treated to form
a smooth finish of uniform texture, appearance and colour This surface finish is required on all exposed formed surfaces unless a class F2
finish is specified.
Unless specified to the contrary, steel forms may be used to form surfaces with a class F3 surface finish.
The use of steel forms shall be permitted to form surfaces for which Class F3 surface finish has been specified, provided that only
undamaged forms shall be used for such work and that the forms shall be subject to the approval of the Engineer.
4. Board surface finish
This finish shall be that obtained by using tongue-and-groove timber boarding arranged in an approved regular pattern. The finish is
intended to be left as struck but surface defects shall be remedied in accordance with Clause A13.2.7.4 and large fins trimmed where
5. Protecting the surfaces
The Contractor shall ensure that permanently exposed concrete surfaces are protected from rust marks, spillage and stains of all kinds and
other damage during construction.
c) Unformed surfaces: Classes of finish
(i) Class U1 surface finish (rough)
This surface finish is required on those portions of bridge decks or culvert decks which are to receive asphalt or concrete surfacing
or which are to be covered by backfilling material.
Where the placing and compacting of the concrete have been completed as specified in Clause A13.4.7.11 the top surface shall
be screeded off with a template to the required cross-section and tamped with a tamping board to compact the surface thoroughly
and to bring mortar to the surface, so as to leave the surface slightly rough but generally at the required elevation.
(ii) Class U2 surface finish (floated)
This surface finish is required on sidewalks; the tops of wing walls and retaining walls; exposed concrete shoulders and
unsurfaced areas on bridge decks; the inverts of box culverts; and decks which are to receive surfacings other than asphalt or
concrete.
The surface shall first be given a class U1 surface finish and after the concrete has hardened sufficiently, it shall be wood-floated
to a uniform surface free from trowel marks. For non-skid surfaces such as on sidewalks and bridge decks, the surface shall then
be given a broom finish. The corrugations so produced shall be approximately 1 mm deep, uniform of appearance and width and
shall be perpendicular to the centre line of the pavement.
(iii) Class U3 surface finish (smoothly finished)
This surface finish shall be required at bearing areas and the tops of concrete railings. The surface shall first be given a class U1
surface finish, and after the concrete has hardened sufficiently, it shall be floated with a steel float to a smooth surface to within the
dimensional tolerances specified in Clause A13.6.8.1.
Rubbing with carborundum stone after the concrete has hardened shall be allowed but under no circumstances will plastering of
the surface be permitted.
d) Formwork for open joints
The requirements for formwork for open joints shall, unless otherwise specified, apply only to cases where the distance between opposite
concrete surfaces is equal to or less than 150 mm.
Formwork for open joints shall be constructed to produce a class F1 surface finish to concealed surfaces or a class F2 or F3 surface finish
corresponding to the in-plane surface finish of the bordering concrete surfaces. The material used and construction of the formwork shall permit
its complete removal to form the open joint. All materials to form open joints shall be completely removed along with the adjacent formwork.
No solvent shall be used to remove formwork unless approved by the Engineer.
e) Openings and wall chases
Openings and wall chases shall be provided only where indicated on the drawings or as authorised by the Engineer. Frames for openings shall
be rigid and firmly secured in position to prevent their moving. Temporary holes shall be so formed that they will not create an irregular pattern
in relation to the rest of the exposed formed concrete surface.
f) Sliding formwork
(i) Plant and equipment
Unless otherwise specified in the Contract Documentation hoisting equipment for sliding formwork, which operates stepwise with
upward movements of between 10 mm and 100 mm will be acceptable. However, the use of linked hydraulic or pneumatic jacks
is preferable, which are reversible and driven by an electrically operated pump, and which can hoist at a steady rate. The jacks
shall have independent controls for regulating verticality and levelness. The jacking system shall ensure that the sliding- formwork
assembly can be hoisted evenly.
The use of hoisting systems which operate without jack rods shall be subject to the approval of the Engineer.
All equipment shall be thoroughly tested and inspected before installation and shall be maintained in a good working order
throughout the entire sliding operation.

The Contractor shall keep adequate back-up plant, equipment and quantities of materials on the site to ensure that the slide
casting can proceed without interruption. All conceivable repairs to this effect, as well as normal day to day maintenance of all
plant and equipment, shall be planned to be undertaken within the time span of a normal daily jacking cycle.
(ii) Instrumentation and monitoring
The Contractor shall supply and install suitable instrumentation on the sliding platform and foundations and against the sides of
the structure for monitoring the height, verticality, levelness and twisting at regular distances. The equipment used, its utilisation
and the frequency of recording any readings shall be approved by the Engineer.
The Contractor shall be responsible for all monitoring work and shall ensure that records of all readings and measurements taken
are filed systematically and are at all times available to the Engineer and the person in control of the sliding operation.
Unless otherwise specified, the verticality of the structure shall be controlled with laser alignment apparatus or optical plummets,
and the levelness of the sliding forms with a water level system with reference control points placed at strategic locations.
Height and verticality shall be monitored at intervals not exceeding 4 hours. The readings shall be plotted immediately on graphs.
When the structure is more than 10 mm out of vertical the Engineer shall be notified immediately.
(iii) Supervision
During the entire period of the sliding operation, a competent person who is fully acquainted with the sliding technique and the
Contractor 's methods of construction shall be in attendance on the sliding platform and in control of the sliding operations. Such
person shall be authorised and capable to take immediate corrective actions in case the sliding operation goes wrong in any way.
(iv) Construction
The jacking frame shall be constructed with adequate clearance between the underside of the cross members and top of the
formwork to allow the horizontal reinforcement and embedded items to be correctly installed. A quality control procedure shall be
agreed on by the Contractor and the Engineer to ensure that all the reinforcement is placed. At all times there shall be horizontal
reinforcement above the level of the top of the formwork panel.
Guides shall be provided to ensure that the vertical reinforcement can be correctly placed and spliced and the specified concrete
cover over the reinforcement maintained.
Where the jack rods are to be recovered, adequate precautions shall be taken in respect of their removal without damage being
caused to the concrete.
Where jack rods occur at openings or wall chases, adequate lateral support shall be provided to prevent their buckling.
Equipment and material shall be so distributed on the working platforms that the load will be evenly distributed over the jacks.
Guard plates shall be provided at the tops of the forms to the outside walls to prevent the concrete from falling down the outside.
The framework, forms and platforms shall be regularly cleared and the accumulation thereon of redundant concrete prevented.
The Contractor shall take all precautions to prevent contamination of the concrete by leaking oil or other causes.
(v) The sliding process
The Contractor shall give the Engineer 24 hours' notice of his intention to commence with slide casting. Permission to commence
with the sliding shall not be given by the Engineer before the sliding-formwork assembly is fully operative and the complete stock
of all materials required for the slide casting as well as back-up plant and equipment are on the site.
The Contractor shall ensure that the rate of sliding is such that the concrete at the bottom of the formwork has obtained sufficient
strength to support itself and all loads which may be placed on the concrete at the time, and that the concrete does not adhere to
the sides of the forms.
The slide-casting operation shall be continuous, without any interruptions, until the full height of the structure has been reached,
and shall be geared and organised so as to maintain an average rate of sliding of 350 mm per hour.
(vi) Interruptions
When the sliding operations are delayed for more than 45 minutes, the Contractor shall prevent adhesion of the setting concrete to
the formwork panels by easing the forms or moving them slightly every 10 minutes, or alternatively, where reversible jacks are
used, by lowering the forms by 10 mm to 25 mm. Wherever interruptions occur, emergency construction joints shall be formed
and treated in accordance with Clause A13.4.7.11g). Before concreting is restarted, the form shall be adjusted to fit snugly onto
the hardened concrete so as to prevent steps from being formed on the exposed concrete surface. When slide casting is
recommenced care shall be taken to prevent the fresh concrete from being lifted off from the old concrete.
g) Permanent formwork
Void formers shall be secured in position at regular intervals to prevent displacement and distortion during concreting. The void formers shall be
supported on precast concrete blocks or rigid welded steel cradles, all subject to approval by the Engineer. The ties securing the void formers
shall be attached to the formwork and cross bearers of the falsework. The void formers shall not be tied to or supported on the reinforcement.
Anchor ties shall be designed to resist full buoyancy forces and details of such shall be submitted to the Engineer for approval. Void formers
shall be held in position in order that no movement exceeding 1 % of the deck thickness takes place during concreting.
The anchor ties shall be placed to coincide with the position of the internal bracing where applicable.
Fibre-cement plates shall be supported so that the plate spans in the direction parallel to the orientation of the fibres.
h) Preparing the formwork
The surfaces of forms which are to be in contact with fresh (wet) concrete shall be treated to ensure non-adhesion of the concrete to the forms
and easy release from the concrete during the stripping of the formwork.

Release agents shall be applied strictly in accordance with the manufacturer's instructions, and every precaution shall be taken to avoid the
contamination of the reinforcement, prestressing tendons and anchorages. In the selection of release agents, due regard shall be given to the
necessity for maintaining a uniform colour and appearance throughout on the exposed concrete surfaces.
Before the concrete is placed, all dirt and foreign matter shall be removed from the forms and the forms shall be thoroughly wetted with water.
i) Vertical, horizontal and inclined formwork
Formwork to the faces of structures with a gradient equal to or greater than eight vertical to one horizontal shall be classified as vertical
formwork.
Formwork to the faces of structures with a gradient less than eight vertical to one horizontal, or equal to or greater than one vertical to eight
horizontal, shall be classified as inclined formwork.
Formwork to the faces of structures with a gradient of less than one vertical to eight horizontal shall be classified as horizontal formwork.
A13.2.7.3 Removing the Falsework and Formwork

a) Considerations for falsework and formwork removal
Falsework and formwork shall not be removed before the concrete has attained sufficient strength to:
(i) support its own mass and any loads which may be imposed on it,
(ii) resist damage to the surfaces during stripping,
(iii) avoid deflections beyond the specified tolerances due to the elastic or inelastic (creep) behaviour of the concrete, and
(iv) avoid cracking beyond specified tolerances, with particular reference to serviceability and durability requirements.
All load bearing falsework and formwork shall not be removed before the Contractor has obtained written authorisation to effect such removal
from the Engineer. The Engineer shall request documentary evidence from the Contractor proving that the in situ concrete has reached the
acceptable strength before stripping. All falsework and formwork shall be carefully removed without exposing the cast concrete to impact,
overload or damage.
b) Technical criteria for falsework and formwork removal
The Engineer shall indicate the minimum strength at which load bearing formwork and falsework for the concrete can safely be struck. In the
absence of particular requirements, the following guidelines shall apply:
(i) The stripping time for slabs and beam soffits shall be the greater of the values derived from consideration of the strength required to:
1. an equivalent in situ concrete strength equal to 2,0 times the stress to which it will be subjected,
2. a minimum in situ concrete strength of 10 MPa.
Where the above cannot be obtained the following minimum stripping times shall always apply:
Table A13.2.7-1: Removing falsework and formwork: Minimum times
Span Length Days
Up to 3,0 m 4
3,0 m up to 6,0 m 10
6,0 m and over 14
(ii) The stripping time for vertical formwork and unloaded columns shall be the greater of the values derived from consideration of the strength
required to:
1. withstand wind loading,
2. the stripping time to avoid early thermal contraction cracking,
3. a minimum in situ concrete strength of 4 MPa
(iii) The stripping time, or minimum strength requirements, for continuously reinforced concrete structures and in particular where a structure is
constructed in stages, for formwork and falsework removal shall be calculated from the last concrete pour and shall be specified on the
drawings and authorised by the Engineer.
(iv) The stripping time, or minimum strength requirements, for all prestressed concrete structures, for formwork and falsework removal shall be
calculated from the last concrete pour and shall only be considered after the full prestressing force relating to the particular stage of
construction has been applied and shall be, submitted to the Engineer for approval and verified by the Engineer as acceptable.
c) Strength estimation
The in situ concrete strength may be determined by the following methods:
(i) Compressive strength test on temperature-matched cubes,
(ii) Compressive strength test on cubes stored and cured under the same conditions as the structural member,
(iii) In situ maturity measurements in accordance with ASTM C1074.
Specialist literature such as the CIRIA Report 136 should be consulted where necessary.
d) Releasing of loads and propping

The loads on falsework shall be released in a sequence that ensures that other falsework members are not subject to excessive loads. Special
attention shall be given to the removal of falsework and formwork for prestressed concrete structures, especially for continuous members so that
unnecessary stresses are not induced into concrete member or element. The falsework shall be released in stages with the stressing of the
bridgedeck in accordance prestressing design and stressing sequence of cables of the bridgedeck. The stability of falsework and formwork shall
be maintained when loads are released and during dismantling.
The procedure for propping or re-propping, when used to reduce the effects of the initial load, the imposed loading, to avoid excessive
deflections, or all combinations thereof, should be detailed in a method statement for the approval of the Engineer.
e) Curing and surface protection
All unformed surfaces shall be kept moist by means described in Clause A13.4.7.12h). Where curing is achieved by retention of the formwork,
the minimum curing period contained in Table A13.4.7-18 shall apply.
A13.2.7.4 Remedial Treatment and Formed Surfaces

a) General
Agreement shall be reached with the Engineer regarding any remedial treatment to be given after the surfaces have been inspected immediately
after the formwork has been removed, which treatment shall be carried out immediately after stripping but before the application of curing
compounds in accordance with Clause A13.4.7.12h). No surfaces may be treated before inspection by the Engineer.
b) Repairs to surface defects

Surface defects such as small areas of honeycombing, cavities produced by form ties, large isolated blow-holes, broken corner edges, etc., shall
be repaired with mortar having a cement and sand ratio equal to that of the concrete being repaired.
For the repair of large or deep areas of honeycombing and defects, special approved methods and techniques, such as sprayed concrete,
pressure grouting, epoxy bonding agents, etc., may be used.
Where, in the opinion of the Engineer, the extent of the honeycombing or defects is of such a degree that doubt exists about the effectiveness of
repair work, the Contractor shall at his own cost perform a load test in accordance with Clause A13.4.8.3 to prove that the structural safety of the
repaired member has not been prejudiced, failing which, the structure shall be rebuilt in part or in full at the Contractor's cost.
Where the concrete has been damaged by adhesion to the formwork panel, the cracked and loose concrete shall be removed; or where the
fresh concrete has lifted off at construction joints, the crack shall be scraped out immediately on both sides of the wall to a depth of at least 50
mm. The cavities so formed shall then be repaired as described above.
In addition to the repairs as defined above the Engineer may allow the methods of repair in accordance with Chapter14 for new concrete.
c) Rubbing the surfaces

If the finish of exposed formed surfaces does not comply with the requirements for uniformity of texture, appearance and colour, the Contractor
shall, when so instructed by the Engineer, rub down the exposed surfaces of the entire structure or of any part of it as specified below.
The surface shall be saturated with water for at least one hour. Initial rubbing shall be done with a medium-coarse carborundum stone, where a
small amount of mortar, having a sand cement ratio equal to that of the concrete being repaired, is used on the surface. Rubbing shall be
continued until all form marks, projections and irregularities have been removed and a uniform surface has been obtained. The paste produced
by the rubbing shall be left in place. The final rubbing shall be carried out with a fine carborundum stone and water. This rubbing shall continue
until the entire surface is of a smooth, even texture and is uniform in colour. The surface shall then be washed with a brush to remove surplus
paste and powder.
Where the concrete surfaces formed by sliding formwork require treatment to achieve the surface finish specified for the member, the concrete
shall, as soon as the surfaces under the formwork are exposed, be floated with rubber- lined floats to the desired finish.
A13.2.8 WORKMANSHIP
For the assessment of acceptance and compliance the tolerances given below shall be the maximum permissible deviations from the
specified dimensions, levels, alignment, positions, etc., shown on the drawings of the structures or structural members.
a) Footings, pile capping slabs, caisson cover slabs, etc.

Position ..................................................................................................................................................................................... 15 mm
Alignment:
Alignment of individual members ..................................................................................................................................................... 5°
Alignment of members as they collectively determine the alignment of the structure as a whole ....................................... 1 minute
Dimensions: Leading dimension in plan ............................................................................................................................... ± 25 mm
Thickness ................................................................................................................................................................ + 25 mm – 15 mm
Levels: Average level of slabs, Footings, etc .......................................................................................................................... ± 25 mm
b) Column, walls, piers, abutments, etc

Position ..................................................................................................................................................................................... 10 mm
Alignment: Alignment of walls piers, Abutment and column groups ..................................................................................... 1 minute
Dimensions:
Leading dimensions of walls, Piers and abutment .................................................................................................................. ± 25 mm

Thickness of walls, piers and abutments and cross-sectional dimensions of columns:
Plus-tolerance ........................................................................................................................................................................... 25 mm
Minus-tolerance: 3 % of the specified dimensions within the range of 5,0 mm to 25 mm
Levels: Average level of finished or trimmed /cut column, piers, walls, abutment, etc ............................................................. ± 10 mm
Verticality:
(i) Using ordinary
Formwork : 1 in 400. Maximum 25 mm
(ii) Using sliding
Formwork : 1 in 200. Maximum 50 mm
Surface regularity:
(i) Using ordinary formwork ............................................................................................................................................... 3,0 mm

(ii) Using sliding formwork .................................................................................................................................................. 6,0 mm
c) Bridge and culvert superstructure

Position ..................................................................................................................................................................................... 10 mm
Alignment: Superstructure as a whole..................................................................................................................................... 1 minute
Dimension:
Leading dimensions in plan ................................................................................................................................................... ± 25 mm
Thickness of slabs, width and depth of beams: plus-tolerance.................................................................................................. 15 mm
Minus-tolerance: 3 % of the specified dimensions within the range of 5,0 mm to 25 mm
Surface regularity (all surfaces other than upper surface of deck) ............................................................................................. 3,0 mm
Bridge and culvert decks, surface tolerances:
The tolerances specified in Clause A5.3.8.4 of Chapter 5 for the base in respect of level, grade, cross-section and surface regularity shall
apply. Surface regularity shall be tested by straight- edge.
d) Precast beams
The following tolerances shall apply to precast beams in addition to the requirements stated in Clause A13.2.8.1c) for the superstructure.
The width of the gap between contiguous beams shall not exceed twice the width of the specified nominal gap shown on the drawings or the
width of the nominal gap plus 40 mm, whichever is the lesser, and the overall width between the outermost beams of the bridge deck shall be
within 40 mm of the specified width.
Straightness or bow: The deviation from the prescribed line measured on the overall length of the beam shall not exceed the following:
(i) In the horizontal plane:
0,5 mm per metre length of the beam within the tolerance range of 6,0 mm to 15 mm.
(ii) In the vertical plane:
(1) I-beams: 2,0 mm per metre length of the beam within the tolerance range of 6, 0 mm t o 20 mm.
(2) Other beams: 1,0 mm per metre length of the beam within the tolerance range of 3,0 mm to 20 mm.
Camber: The soffits of adjacent beams when placed side by side on the bridge deck shall not at any place differ by more than 2,0 mm per
metre length of the beam within the tolerance range of 6,0 mm to 20 mm
The lengths of precast beams before stressing shall be ± 0 , 1 % o f the total length within the tolerance range of ± 5,0 mm to ± 20
mm.
Surfacing regularity................................................................................................................................................................... 3,0 mm
e) Miscellaneous
(i) Chamfers
Fillets used for forming chamfers shall be within a tolerance of 2,0 mm in cross-sectional dimensions, and the actual chamfer
on the concrete shall not vary by more than 3,0 mm from the specified dimensions.
(ii) Barriers, parapets, railings, footwalks, kerbs and copings etc.
The members shall be constructed within a tolerance ± 5,0 mm for all dimensions. The alignment shall not deviate from the true
alignment by more than 10 mm in any place, nor shall the alignment deviate by more than 5,0 mm from the true alignment over
any length of 5,0 m.
Notwithstanding the above the levels on the above elements shall be fitted to give a smooth, aesthetic vertical alignment.

B13.2 FALSEWORK, FORMWORK AND CONCRETE FINISH
CONTENTS
B13.2.1 SCOPE
B13.2.2 DEFINITIONS
B13.2.3 GENERAL
B13.2.5 MATERIALS
B13.2.8 WORKMANSHIP
B13.2.1 SCOPE
This Section covers the design, supply and erection of all falsework and formwork used in the construction of permanent work. This Section also
describes the classes of surface finishes on formed and unformed concrete surfaces. Most of the activities are executed by labour at various
skill levels, therefore the specifications derived in Part A can be deemed suitable for labour enhanced work.
B13.2.2 DEFINITIONS
B13.2.3 GENERAL

B13.2.5 MATERIALS


B13.2.8 WORKMANSHIP

C13.2 FALSEWORK, FORMWORK AND CONCRETE FINISH
(i) Preamble
None.
pay items.

C13.2.1 Formwork to provide (class of finish indicated as F1, F2, F3 or board) surface finish to square metre (m2)
(description of member to which applicable)
C13.2.2 Vertical formwork to provide (class of finish indicated as F1, F2, F3 or board) surface square metre (m2)
finish to (description of member to which applicable)
C13.2.3 Horizontal formwork to provide (class of finish Indicated as F1, F2, F3 or board) surface square metre (m2)
C13.2.4 Inclined formwork to provide (class of finish indicated as F1, F2, F3 or board) surface square metre (m2)
The unit of measurement shall be the square metre, and only the actual area of formwork in contact with the finished face of the concrete shall
be measured. Formwork for the different classes of finish shall be measured separately. Formwork for construction joints shall be measured for
payment under class F1 surface finish, but only formwork for mandatory construction joints shall be measured for payment.
The tendered rates shall include full compensation for procuring and furnishing all materials required, erecting the falsework and formwork,
constructing the forms, forming the grooves, fillets. chamfers up to 100 mm and stop-ends for construction joints, treating and preparing the
forms, all bolts, nuts, ties, struts and stays, stripping and removing the formwork after completion of the work, all labour, equipment and
incidentals, and rubbing and surface treatment. Payment of 80 % of the amount due for formwork will be made when the formwork has been
removed, and payment of the remaining 20 % will be made on approval of the concrete surface finish.

C13.2.5 Permanent formwork

C13.2.5.1 To form voids of (diameter/ size of void indicated) in (description of member to which square metre (m2)
applicable)
C13.2.5.2 Of (description of material and member to which applicable) square metre (m2)
The unit of measurement shall be the square metre of concrete area formed with permanent formwork.
The tendered rates shall include full compensation for procuring and furnishing all the materials required, installing the formwork, and labour,
equipment and incidentials.
The tendered rates shall include for the installation of permanent drainage holes within the void formers at the low points of each void.
C13.2.6 Formwork to form open joints (description of member to which applicable, and location) square metre (m2)
The unit of measurement shall be the square metre of concrete area formed
Surfaces formed prior to the construction of the final surface for completing the joint, shall be measured under Items C13.2.1, C13.2.2, C13.2.3
or C13.2.4, as may be applicable.
The tendered rate shall include full compensation for procuring and furnishing all the materials required, constructing the formwork and
subsequently removing all the material within the joint space, as well as labour, equipment and Incidentals. Payment for formwork to open joints
shall be made only after the forms and filler material have been completely removed and approval of the surface finish has been obtained.
C13.2.7 Establishment on the site for sliding formwork operations lump sum
The tendered lump sum shall include full compensation for the establishment on the site and the subsequent removal of the complete sliding-
formwork assembly, special plant and equipment, and incidentals for the sliding work, the cost of which does not vary with the actual amount of
sliding work done.
This work will be paid for by way of a lump sum, 75 % of which will become payable when the manual is approved, sliding-formwork assembly,
plant and equipment have been fully Installed and commissioned at the first structural member on the site, and the remaining 25 % will become
payable after all sliding work has been completed and the said items have been removed from the site.

C13.2.8 Transporting to and setting up the sliding formwork assembly at (description of each number (No)
structure)
The unit of measurement shall be the number of following similar structures to which the complete sliding-formwork assembly has to be
transported and re-erected in position ready to be commissioned, after successful completion of the first structure.
The tendered rate shall include full compensation for all costs involved in dismantling, transporting and re-erecting of the complete sliding-
formwork assembly.

C13.2.9 Forming the concrete by sliding formwork for (description of each structure and class of metre (m)
surface finish to exposed surfaces indicated)
The unit of measurement shall be the metre height of each structure formed by sliding formwork. The quantity measured shall be the actual
height of each structure formed by the sliding technique.
The tendered rate shall include full compensation for sliding, instrumentation and monitoring, the maintenance of the complete sliding-formwork
assembly, plant and equipment, supplying, installing and recovering the jack rods, floating, repairing and treating the concrete surfaces, forming
the emergency construction joints, and all labour, equipment and Incidentals.
C13.2.10 Provision of designs and drawings of falsework and formwork by an ECSA registered lump sum
Professional Engineer or Technologist (description of member to which applicable)
The unit of measurement shall be the lump sum and shall be paid in two payments of 50 % on submission of the falsework and formwork
designs and the second 50 % on complete removal of all the falsework.
The tendered rates shall include full compensation for procuring and provision of all drawings for the falsework and formwork designs by an
ECSA registered professional, including inspections, supervision where applicable, all labour, material, travelling and incidentals, and the signing
off on the erection of the falsework and formwork including submission of all certificates as specified.

D13.2 FALSEWORK, FORMWORK AND CONCRETE FINISH
CONTENTS
D13.2.1 SCOPE
D13.2.2 GENERAL
D13.2.1 SCOPE
• Product conformance specifications
• Warranties for product or element design and installation of proprietary systems
• Performance specifications
Note that the requirements for performance specifications are not limited to that given in Part C only but includes all of the requirements in the
D13.2.2 GENERAL
D13.2.2.1 Product conformance specifications
Conformance documentation shall be provided for the following, if required for the execution of the work as specified:
a. Steel falsework members.
b. Timber falsework members.
c. Jacks, devices, clamps and fittings.
d. Steel and Timber formwork.
e. Material in permanent Void formers.

D13.2.3.1 Warranties for product or element design and installation of proprietary systems
Certification for erection of falsework and formwork by a suitably experienced ECSA Registered Professional Engineer or Technologist is
required.
D13.2.3.2 Performance specifications

Performance based specifications shall be contained in the Contract Documentation for the project, if applicable.

13.3 STEEL REINFORCEMENT
CONTENTS
A13.3.1 SCOPE
A13.3.2 DEFINITIONS
A13.3.3 GENERAL
A13.3.5 MATERIALS
A13.3.8 WORKMANSHIP

A13.3 STEEL REINFORCEMENT

A13.3.1 SCOPE
This Section covers the furnishing and placing of reinforcing steel in concrete structures.
A13.3.2 DEFINITIONS
Cover - shall mean the minimum thickness of concrete between the surface of the outermost reinforcement and the face of the concrete.
A13.3.3 GENERAL
the Engineer.


A13.3.5 MATERIALS
A13.3.5.1 Steel bars
Steel reinforcing bars shall comply with the requirements of SANS 920. For each consignment of steel reinforcement delivered on the site, the
Contractor shall submit a certificate issued by a recognised testing authority to confirm that the steel complies with the specified requirements.
Cold-worked reinforcing bars shall not be used.
The type of bar required shall be indicated on the drawings by the symbols R, Y or Z in accordance with SANS 282.
A13.3.5.2 Welded steel fabric

Welded steel fabric shall comply with the requirements of SANS 1024.
A13.3.5.3 Mechanical couplers

The tensile properties determined on a test sample with a maximum gauge length of 610 mm, and which consists of reinforcing bars butt-jointed
by a mechanical coupler shall comply with the following requirements:
(a) When tested in accordance with the relevant requirements of Clause 5.3 of SANS 920, the tensile properties of the test sample shall show
an improvement of at least 10 % on the requirements of Clause 3.7 of SANS 920.
(b) Where the test sample is subjected to a load equal to 0,58 of the specified minimum yield force of the bar, the elongation measured on the
gauge length shall not exceed the calculated theoretical elongation for a 610 mm length of the bar, based on a stress of 0,58 of the
specified minimum yield stress of the bar and a Young's modulus of 200 GPa.
The Contractor shall submit to the Engineer test certificates from a recognised testing authority to confirm that the tensile couplers offered
comply with the specified requirements.
All mechanical couplers used shall be subject to the approval of the Engineer.

A13.3.7.1 Storing the materials
Reinforcing steel shall be stacked off the ground and in aggressive environments it shall be stored under cover.
A13.3.7.2 Bending the reinforcing steel

Reinforcement shall be cut or cut and bent to the dimensions shown on the bending schedules and in accordance with SANS 282.
No flame-cutting of high-tensile steel bars shall be permitted except when authorised.
Except as described below, all bars shall be bent cold and bending shall be done slowly, a steady, even pressure being exerted without jerking
or impact.
If approved, the hot bending of bars of at least 32 mm in diameter will be permitted, provided that the bars do not depend on cold working for
their strength. When hot bending is approved, the bars shall be heated slowly to a cherry-red heat (not exceeding 840C) and shall be allowed to
cool slowly in air after bending. Quenching with water shall not be permitted.
Already bent reinforcing bars shall not be rebent at the same position without authorisation.
A13.3.7.3 Placing and fixing

Reinforcement shall be positioned as shown on the drawings and shall be firmly secured in position within the tolerance given in Clauses
A13.3.8.4 and A13.4.8.1a)(iv) by being tied with 1,6 mm or 1,25 mm diameter annealed wire or by suitable clips being used, or, where
authorised by the Engineer, by tack welding. Tying wires for steel bars shall be bent back after tying and not cut off into the formwork.
The concrete cover over the projecting ends of ties or clamps shall comply with the specifications for concrete cover over reinforcement.
Where protruding bars are exposed to the elements for an indefinite period, the bars shall be adequately protected against corrosion and
damage and shall be properly cleaned before being permanently encased in concrete.
In members which are formed with sliding formwork, spacer ladders for placing and fixing the wall reinforcement shall be used at spacings
indicated on the drawings or as prescribed by the Engineer. The spacer ladders shall consist of two bars 3,7 m in length with ties 4 mm in
diameter welded to them to resemble a ladder. The ties shall be spaced at multiples of the horizontal bar spacing in the wall, and shall be used
to secure the horizontal reinforcement. The laps in the horizontal reinforcement shall be staggered to ensure that no part of two laps in any four
consecutive layers lie in the same vertical plane.
A13.3.7.4 Cover and supports

The minimum cover shall be as shown on the drawings. Where no cover is indicated, the Contractor shall inform the Engineer who shall, in
consultation with the design Engineer, indicate the required cover in writing and the record drawings shall indicate such cover.

The cover shall be increased by the expected depth of any surface treatment, e.g. when concrete is bush hammered or when rebates are
provided.
The cover blocks or spacers required for ensuring that the specified cover is obtained shall be made of concrete. The cover and spacer blocks
and their spacing shall be as small as may be consistent with their use. Prior to fixing the steel, samples of the proposed cover and spacer
blocks shall be submitted to the Engineer for approval, along with a written statement for on-site manufacture, if applicable.
Cover blocks of other materials shall only be used with the Engineer’s approval. However, only concrete cover blocks may be used for exposed
surfaces.
Concrete spacer blocks shall be made with 7,1 mm maximum sized aggregate and shall be of the same strength, cementitious binder, and
aggregate type as those of the surrounding concrete. The blocks shall be hemi-spherical in shape and shall be formed in specially manufactured
moulds and the concrete well compacted and cured under water for a period of at least 14 days, all to the satisfaction of the Engineer.
Ties cast into spacer blocks shall be galvanized and shall not extend deeper into the spacer block than half the depth of the spacer block.
The Contractor shall provide stools for support as shown on the drawings, or, where they are not detailed on the drawings, wherever the
Engineer requires them to be installed. The stools shall be suitably robust, and fixed securely so that they cannot swivel or move. The stools
shall have sufficient strength to perform the required functions, taking into account amongst others temporary loads such as the weight of
workmen and wet concrete, and forces caused by vibrators and other methods of compacting the concrete.
A13.3.7.5 Laps and joints

Laps, joints, splices and mechanical couplings shall be applied only by the specified methods and at the positions shown on the drawings or as
authorised.
A13.3.8 WORKMANSHIP
A13.3.8.1 Surface condition
When the concrete is placed around the reinforcing steel, the reinforcing steel shall be clean, free from mud, oil, grease, paint, loose rust, loose
mill scale or any other substance which could have an adverse chemical effect on the steel or concrete, or which could reduce the bond.
A13.3.8.2 Welding
Reinforcement shall be welded only where shown on the drawings or as authorised.
All welding shall be done in a controlled environment.
Flash butt welding shall be done only with the combination of flashing, heating, upsetting and annealing to the satisfaction of the Engineer, and
only those machines which control this cycle of operations automatically shall be used.
Metal-arc welding of reinforcement shall be done in accordance with BS EN 1011, and with the recommendations of the reinforcement
manufacturers, subject to approval by the Engineer and the satisfactory performance of trial joints. Hot-rolled high-yield-stress steel shall be
preheated to between 240C and 280C and low-hydrogen electrodes only may be used.
Trial welding joints shall be made on the site in circumstances similar to those which will govern during the making of production welding joints
by the person who will be responsible for the production welding joints.
Other methods of welding e.g. resistance welding, may be used subject to approval by the Engineer and to their satisfactory performance in trial
joints.
Welded joints shall be full-strength welds and their strength shall be assessed by destruction tests on samples selected by the Engineer.
A13.3.8.3 Storage of materials

Stacking of reinforcing steel shall be executed under the supervision of persons with specific knowledge and experience. Any support structure
used for stacking shall be structurally sound and shall be able to support the reinforcing steel.
In addition to the requirements given below, the reinforcing steel shall be neatly and accurately fixed in a manner which is consistent with proper
workmanship and the structural integrity of the structural member.
Specifically the following requirements shall apply:
a) Tension steel
The actual position of tension steel shall not deviate from the true position by a distance which would reduce the effective lever arm by more
than 2 % of the overall depth of the member, or 10 mm, whichever is the greater.
b) Concrete cover
The concrete cover on reinforcing steel shall nowhere be less than the specified cover, reduced by the tolerance given in Clause A13.4.8.1a)(iv).
c) Spacing between bars
The spacing between closely spaced parallel bars, especially in beams and columns, shall, unless otherwise specified, be not less than the
maximum size of the aggregate used in the concrete plus 5,0 mm.

d) Bending of reinforcement
The requirements of SANS 282 regarding dimensional tolerances for cutting and bending of the reinforcing steel shall apply, with the proviso that
the other requirements set out in this Clause shall be complied with even if the tolerances in SANS 282 are not exceeded.

B13.3 STEEL REINFORCEMENT
CONTENTS
B13.3.1 SCOPE
B13.3.2 DEFINITIONS
B13.3.3 GENERAL
B13.3.5 MATERIALS
B13.3.8 WORKMANSHIP
B13.3.1 SCOPE
This Section covers the furnishing and placing of reinforcing steel in concrete structures. This is deemed to be ideally suited for labour
enhanced work at varying skills level, therefore provisions provided in Part A, shall apply
B13.3.2 DEFINITIONS
B13.3.3 GENERAL

B13.3.5 MATERIALS


B13.3.8 WORKMANSHIP

C13.3 STEEL REINFORCEMENT
(i) Preamble
None.
pay items.
Concrete Cover C13.3.1 C20.1.2.1d) of Chapter 20
C13.3.1 Reinforcement for:
C13.3.1.1 (Description of portion of structure to which applicable):
(a) Mild-steel bars ton (t)
(b) High-yield-stress-steel bars (type indicated) ton (t)
(c) Welded Steel Fabric kilogram (kg)
(d) Stainless steel bars (type indicated) ton (t)
(e) Other Materials (specify material) ton (t)
C13.3.1.2 Etc. for other structures or parts of structures ton (t)

The unit of measurement for steel bars shall be the ton of reinforcing steel in place in accordance with the drawings or as authorised.

The unit of measurement for welded steel fabric shall be the kilogram of welded steel fabric in place, the quantity of which shall be calculated from
the nett area of the mesh used in accordance with the drawings or as authorised.
Ties, stools and other steel used for positioning the reinforcing steel shall be measured as steel reinforcement under the appropriate sub-item.
The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding, trial weld joints, placing and fixing the steel
reinforcement, including all tying wire, spacers and waste.
Where the concrete cover specified has not been achieved after cover tests have been carried out in accordance with Clause A13.4.7.10f) reduced
payment as determined under Clause A20.1.7.6 of Chapter 20 shall be applied to all the relevant pay items under Section C13.3.
C13.3.2 Mechanical couplers (type of coupler and diameter of bar indicated) number (No)
The unit of measurement shall be the number of mechanical couplers for each bar diameter installed.
The tendered rate shall include full compensation for supplying all the material, preparing and modifying the bar ends to be joined, and all tools,
equipment and labour required for completing the work.
C13.3.3 Spacer ladders for (description of part of structure to which applicable) ton (t)
The unit of measurement for spacer ladders shall be the ton of steel in place in accordance with the drawings or as authorised.
The tendered rate shall include full compensation for supplying, delivering, cutting, bending, welding, placing and fixing the ladders, including all tying
wire, spacers and waste.
C13.3.4 Extra-over item C13.3.1 (a), (b), etc. for galvanising of reinforcement ton (t)
The unit of measurement shall be the ton of reinforcing steel hot-dip galvanised with an 85 micrometre coating in accordance with the detail on the
drawings, SANS 121 and Clause A13.9.7.1m).
The tendered rate shall include full compensation for all materials, labour, tools and equipment required to galvanise the specific bars of
reinforcement as required as well as transporting and handling costs.

D13.3 STEEL REINFORCEMENT
CONTENTS
D13.3.1 SCOPE
D13.3.2 GENERAL
D13.3.1 SCOPE
D13.3.2 GENERAL
Conformance documentation shall be provided for:
(a) Steel reinforcement: each type and batch;
(b) Galvanising of steel reinforcement
(c) Welding of reinforcement, where relevant; and
(d) Mechanical couplers.
(e) Stainless Steel.
(f) Other special materials.

No additional requirements.

Performance based specifications shall be contained in the Contract Documentation for the project.

13.4 CONCRETE
CONTENTS
A13.4.1 SCOPE
A13.4.2 DEFINITIONS
A13.4.3 GENERAL
A13.4.5 MATERIALS
A13.4.8 WORKMANSHIP

A13.4 CONCRETE
A13.4.1 SCOPE
This Section covers the supply and storage or stockpile of all materials, manufacture, transport, placing, finishing, curing, protection and testing
concrete in bridges, culverts and miscellaneous structures. The completed concrete elements shall conform to the lines, grades, and
dimensions shown on the drawings and as specified in Section A13.2. The work includes elements of structures constructed by cast-in-place
and precast methods using either plain (unreinforced), reinforced, or prestressed concrete or any combination thereof.
A13.4.2 DEFINITIONS
Characteristic strength - characteristic strength of concrete is the compressive cylinder or cube strength below which no more than 5 % of the
test results in a statistical population shall fall, tested as specified in Section A20.1 and applicable Clauses of Chapter 20.
Environment - the physical and chemical actions to which the concrete is exposed and which results in effects on the concrete or reinforcement
that are not considered as loads in structural design.
Fresh phase of concrete - concrete that has been fully mixed, that has not yet reached initial set and is still capable of being compacted by the
chosen method.
Hardened phase of concrete - concrete in a solid state and which has developed a certain amount of strength.
Normal-Weight Concrete - concrete in the oven –dry state having a density greater than 2000 kg per cubic metre but not exceeding 2600 kg
per cubic metre, determined in accordance with SANS 3001-C02-8.
Self-compacting concrete - concrete that is able to flow and compact under its own weight, fill the formwork with its reinforcement, ducts, etc.,
while remaining homogeneous.
Valid test result (Fcu) - a valid test result, for the purpose of evaluating compressive strength, shall comprise of the arithmetic mean of three
cube or cylinder specimens where the difference between the highest and lowest result does not exceed 15 % of the arithmetic mean of the
specimens.
Water: cementitious binder ratio - the ratio of the total water content to total cementitious binder content by mass in the mixed concrete.
A13.4.3 GENERAL
This section describes work that encompasses the design, production and placing of concrete conforming to the set of performance criteria in
both the fresh and hardened phases. Irrespective of the originating concrete supply and production source, for example commercially-sourced
ready mixed concrete or precast concrete, the Contractor shall ensure the full conformance to all aspects of this specification.

the Engineer.


The Contractor shall design and be responsible for the performance of all concrete mixes used in structures. The mixture proportions selected
shall produce concrete that is able to be sufficiently worked and finished for all uses intended and shall produce concrete of desired strength,
durability and particular performance requirements in both the fresh and hardened phases as specified. The mix design shall be based upon
obtaining an average concrete compressive strength sufficiently above the specified characteristic compressive strength considering the
expected variability of the concrete and test procedures. Concrete durability index and post-concreting cover testing shall individually comply
with stated minimum or maximum values or specified nominal values adjusted by permissible deviations. Mix designs may be modified during
the course of the work when necessary to ensure compliance with strength, durability parameters and consistence requirements, provided such
changes meet the approval of the Engineer.
The concrete mix design and preconstruction laboratory test results shall be recorded and submitted for approval prior to the commencement of
concreting activities. The concrete operations shall only commence with the approval of the concrete mix design. The Contractor shall
adequately allow sufficient time in his programme for the design and approval of the concrete mix design, particularly where durable concrete is
applicable.
A13.4.5 MATERIALS
The cementitious binder shall comprise either cement, complying with SANS 50197-1, or an approved site blend of such cement and
supplementary cementitious materials that take appropriate cognizance of environmental conditions, durability and strength requirements of the
structural member. The site blending of cement with supplementary cementitious materials shall only be conducted on the basis of an
acceptable quality assurance system approved by the Engineer. Further limitations of the cementitious binder for prestressed concrete
members or units shall be strictly enforced. The cementitious binder shall comprise the following:
a) Cement
Cement shall comply with SANS 50197-1 (EN 197-1) with a strength class of 32,5 or greater, and a rate of strength gain N or greater. Cement
shall hold valid certification in the form of a Letter of Authority issued as certified approval pursuant to the Compulsory Specification for cement
published by Government Notice R.544. Masonry cement shall not be used.
In order to promote resource sustainability principles, cement shall have a maximum average carbon dioxide emission value of 925 kg CO2e
per ton, determined in accordance with the World Business Council for Sustainable Development Greenhouse Gas Protocol.
b) Supplementary cementitious materials
Additional supplementary cementitious materials may be added at the batchplant and used to replace specific proportions of the cementitious
binder. The maximum supplementary cementitious material replacement values shall be cumulative, comprising proportions both pre-blended
into the cement and supplementary cementitious materials added at the batchplant. The further blending of cements that contain a factory-
blended proportion of supplementary cementitious materials exceeding 5 % by mass of cement, except in the particular case of limestone, with
supplementary cementitious materials of a different generic type or nature, e.g. site-based ternary blending, shall not be permitted. The site
blending of CEM III/B, CEM III/C, CEM IV/B and CEM V cements with supplementary cementitious materials shall not be permitted.
Supplementary cementitious materials added at the site batchplant shall be classified and conform to the following requirements:
(i) Ground granulated blastfurnace slag or ground granulated corex slag, conforming to SANS 55167-1, up to maximum cumulative
replacement value of 65 % by mass of cementitious binder;
(ii) Fly ash, conforming to SANS 50450-1, up to maximum cumulative replacement value of 40 % by mass of cementitious binder;

(iii) Silica fume, conforming to SANS 53263-1, up to maximum cumulative replacement value of 10 % by mass of cementitious binder; or
(iv) Other supplementary cementitious materials, blends of supplementary cementitious materials, and appropriate proportions thereof, shall
be generally accepted by the construction industry and approved by the Engineer for use in concrete on the basis of published,
comprehensive long-term research including in-field performance tests conducted over a minimum period of 10 years in a range of typical
African exposure environments.
c) Particular requirements for prestressed concrete
In prestressed concrete members, only the use of CEM I and CEM II cements with a strength class of 42,5 or greater, and a rate of strength
gain N or R, shall be permitted. A site blend of cement and ground granulated blast furnace slag or ground granulated corex slay conforming to
SANS 55167-1 up to a maximum cumulative replacement value of 40 %, fly ash conforming to SANS 50450-1 up to a maximum replacement
value of 20 %, or silica fume, conforming to SANS 53263-1 up to a maximum replacement value of 7 %, by mass of total cementitious binder
may be used only if authorised in the Contract Documentation or by the Engineer in writing.
A13.4.5.2 Aggregates
All aggregates for concrete shall fully comply with the requirements of SANS 1083, subject to the following amendments and additional project
requirements:
a) Coarse aggregates
(i) The flakiness index of the coarse aggregate as determined by SANS 3001-AG4 shall not exceed 35;
(ii) The 10 % FACT value as determined by SANS 3001-AG10 shall be minimum 150 kN when tested dry or minimum 110 kN when tested
wet;
(iii) Alternatively to the 10 % FACT and if required by the Contract Documentation, the aggregate crushing value as determined by
SANS 3001-AG10 shall be maximum 25 % by mass; and
(iv) The soundness of mudrock, shale, basalt and dolomitic aggregates as determined in accordance with SANS 3001-AG13 shall have
maximum 15 % mass loss where magnesium sulfate is used.
b) Fine aggregates
(i) The fineness modulus of the fine aggregate as determined by SANS 3001-PR5 shall not vary by more than ± 0,2 from the approved
modulus;
(ii) The sand equivalent of the fine aggregate shall be determined in accordance with SANS 3001-AG5 and shall be minimum 65 %. The
sand equivalent shall be considered as an indicator test, together with the clay content and methylene blue absorption value, where
non-compliance may be established. However the satisfactory performance in concrete shall be evaluated by drying-shrinkage tests in
accordance with Clause A13.4.5.2c)(i); and
(iii) Tests for organic impurities in natural sands shall be determined in accordance with SANS 5832 and shall be not darker than the
reference solution.
c) Additional project requirements
(i) The drying-shrinkage of both the fine and coarse aggregate, when either is obtained from the Karoo Series or from newly developed
sources, shall be tested in accordance with SANS-AG-33 (SANS 5836) shall not exceed the following limits:
1. For use in prestressed concrete, concrete bridge decks and slender columns the shrinkage of both fine and coarse aggregate shall
not exceed 150 % of that of the reference aggregates;
2. For use in other reinforced concrete members the shrinkage of the fine aggregate shall not exceed 200 %, and of the coarse
aggregate 175 %, of that of the reference aggregates; and
3. For use in mass concrete substructures and unreinforced concrete head walls and wing walls, the shrinkage of both the fine and
coarse aggregate shall not exceed 235 % of that of the reference aggregates.
(ii) Aggregates shall not contain any deleterious amounts of organic materials such as grass, timber or similar materials, as assessed by
visual inspection;
(iii) Where instructed by the Engineer, aggregates shall be checked and shall be free of the following deleterious substances:
1. Tests for the presence of sugar shall be determined in accordance with SANS 3001-AG-30 (SANS 5833) and shall be free from the
presence of sugar;
2. Tests for soluble deleterious impurities shall be conducted in accordance with SANS 3001-AG-31 (SANS 5834) and shall have
minimum compressive strength of 85 % of the reference;
3. Test for the presence of material of low density shall be determined in accordance with SANS 5837 and shall have maximum 0,5
% by mass;
4. Tests for soluble salts shall be determined in accordance with SANS 3001-AG-40 (SANS 5849) and shall have maximum 0,5 % by
mass;
5. Tests for water soluble sulfates shall be determined in accordance with SANS 3001-AG-31 (SANS 5850-1) and shall have
maximum 0,2 % SO3 by mass; and
6. Tests for the presence of shell shall be determined in accordance with SANS 3001-AG-35 (SANS 5840) and shall be maximum
5 % by mass of unbroken shell, or maximum 25 % by mass of broken shell fragments, in the coarse aggregate.
(iv) Where there is any danger of a particular combination of aggregate and cementitious binder giving rise to a harmful alkali-aggregate
reaction, the particular combination shall be tested in accordance with SANS 6245 as described in Clause A13.4.7.2a), and where the
result points to such reaction, either the aggregate or the cementitious binder or both shall be replaced so that an acceptable
combination may be obtained; and
(v) Where aggregate size of larger than 28 mm is used in concrete, the aggregate shall be supplied in two nominal sizes, and the smaller
shall be either 20 mm or 14 mm. The relative proportions of larger and smaller nominal sized aggregate shall be determined by the mix
design.

d) Plums and boulders
Plums and boulders may be used in plain (unreinforced) concrete elements with a minimum thickness of 350 mm and be included to replace
concrete for up to 20 % of the total volume, subject to the following requirements:
(i) The plums and boulders shall be clean, and have no adhering films or coatings;
(ii) The aggregate crushing value may not exceed 25 % and all plums and boulders shall be hard, durable, unweathered and inert;
(iii) The mass of each plum and boulder shall be between 15 kg and 55 kg;
(iv) Each plum or boulder is surrounded by at least 80 mm of concrete when placed;
(v) Each plum or boulder is more or less rounded or cubic in shape with no dimension being less than 60 % of the longest dimension; and
(vi) No dimension of any plum or boulder shall be less than 150 mm or exceed 500 mm.
A13.4.5.3 Water
The Contractor shall prove by way of laboratory tests that all water used for mixing and curing concrete complies with SANS 51008.
A13.4.5.4 Admixtures
The use of admixtures is encouraged to produce durable concrete and to achieve particular fresh phase properties of concrete. All admixtures
for concrete shall comply with the requirements of SANS 50934 (EN 934), ASTM C494 or AASHTO M194. Admixtures shall be of a brand
approved by the Engineer and type compatible with the exposure environment and cementitious binder composition. Admixtures shall have no
deleterious effects on the reinforcement, prestressing or concrete, and shall not contain any chlorides, nitrates, sulphides or sulphites, which
may be detrimental to the reinforcement. Admixtures shall generally be supplied in liquid form and accurately dispensed by a mechanical
dosing unit in a manner appropriate to the method batching e.g. dry versus wet batching. Unless extraordinary circumstances dictate
otherwise, under no circumstances shall a mixture be dispensed on to mix components. Where extraordinary circumstances do exist, other
methods of feeding into the concrete mixture shall be agreed with the Engineer. Where specified, air entraining agents may alternatively comply
with the requirements of SANS 50934 (EN 934), ASTM C260 or AASHTO M154.
Where combinations of two or more admixtures are utilised, they shall be tested for compatibility.
The total amount of admixtures shall not exceed the maximum dosage recommended by the admixture producer and also shall not exceed 5 %
by mass of the total cementitious binder, unless the influence of the higher dosage of admixture on the performance and durability of the
concrete is established and taken into account.
If the total quantity of liquid admixture equals or exceeds 3 litres per cubic metre of concrete, the admixture quantity shall be included in the
water content of the concrete mixture when calculating the water: cementitious binder ratio.
The alkali content (Na2O-equivalent) of all admixtures shall form part of the calculation of the alkali content of concrete in order to limit the
degree of reactivity as specified in Clause A13.4.7.2a).
A13.4.5.5 Integral permeability reducing technology

Where water-tight concrete is indicated on the drawings, the concrete shall incorporate a crystalline permeability reducing additive or alternative
technology with proven effectiveness against hydrostatic pressure, approved by the Engineer. The Contractor shall supply the Engineer with
documented evidence, published by an independent laboratory meeting the requirements of ASTM E329 or Board of Agrément certification,
that the crystallising capability of the permeability reducing technology is evidenced by independent Scanning Electron Microscope photographs
verifying crystalline formations within the concrete matrix.
The integral permeability reducing technology shall be tested in accordance with either: EN12390-8 for applications up to 18 m head or US
Army Corps of Engineers CRD-C48-73 or later. “Permeability of concrete” for applications greater than 18 m head. Minimum performance
criteria for testing according to EN 12390-8 shall be maximum water penetration of 30 mm while for testing according to CRD-C73 (or later)
treated specimens shall exhibit no measurable leakage after pressure testing to 1,05 MPa (equivalent to 106 m head of water). The integral
permeability reducing technology shall also have demonstrable benefits proving self-healing capability, improved chemical resistance to
sulphuric acid exposure, improved compressive strength, and certified approval for use on structures holding potable water. The dosage of the
integral permeability reducing technology shall be recommended by the product manufacturer to achieve the minimum performance criteria per
test method but shall not be less than shown in Table A13.4.5-1.
Table A13.4.5-1: Minimum dosage of integral permeability reducing technology
Water cementitious binder ratio Minimum dosage of integral permeability
reducing technology (% weight of
cementitious binder)
Less than 0,40 0,8 %
0,40 – 0,49 1,0 %
0,50 – 0,54 1,5 %
0,55 – 0,59 2,0 %
0,60 or greater 3,0 %
A13.4.5.6 Fibres
Steel fibres for concrete shall comply with EN 14889-1 or ASTM A820 and polymer fibres shall comply with EN 14889-2 or ASTM D7508. Fibres
shall be submitted to the Engineer for approval prior to the commencement of work.

A13.4.5.7 Pigments and integral colouring agents
Pigments and integral colouring agents for concrete shall comply with ASTM C979 or EN 12878, in particular only Category B pigments shall be
used for reinforced or prestressed concrete.
A13.4.5.8 Evaporation retarders

Protection of the concrete during the plastic phase, should be carried out continuously from time of concrete casting, until initial set is achieved
(normally coincides with cessation of bleeding and commencement of final surface finishing with power floats etc). Where liquid evaporation
retarders are used to effect protection of the concrete, they shall be supplied by a reputable admixture manufacturer and shall be approved by
the Engineer. They shall be applied immediately after compaction of the concrete and initial screeding of the concrete has been completed, with
the proviso that this is as soon as possible after the concrete has been cast. Evaporation retarders shall be applied using a fine mist sprayer, at
a rate recommended by the manufacturer. Environmental conditions experienced on sites may necessitate several applications during the
concrete fresh (plastic) phase.
A13.4.5.9 Curing compounds

Liquid membrane-forming compounds used to cure concrete shall be tested in accordance with SANS 418 (ASTM C156) and shall comply with
the requirements of SANS 423 (ASTM C309), except that the water loss requirement be substituted with the efficiency-index as determined in
accordance with BS 7542. The efficiency-index shall exceed 90 % at an application rate as recommended by the manufacturer, or where no
application rate has been recommended 0,2 litre per square metre. Only suitable application equipment as prescribed by the product supplier
shall be used. A recent test certificate certifying that the curing compound complies with the specifications at the recommended application rate,
with a maximum validity period of 12 months, issued by an approved independent testing laboratory shall be submitted to the Engineer. All
curing compounds and the proposed application rate shall be approved by the Engineer. Due caution should be exercised when selecting
curing compounds to avoid curing compounds that discolour, stain or damage the concrete surface or reduce the adhesion of future concrete or
coatings. No water-based curing compounds are to be used.
A13.4.5.10 Storing the materials

a) General
All constituent materials shall be stored and handled so that their properties do not change, for example due to climate conditions, intermingling
or contamination, and that their conformity with the respective standard is maintained.
b) Cement and supplementary cementitious materials
Cement and supplementary cementitious materials stored on the site shall be kept separately under cover which provides adequate protection
against moisture and other factors which may promote deterioration of the cement or supplementary cementitious material.
Cement and supplementary cementitious material may only be used if stored and maintained at a temperature less than 45°C. In hot weather
concreting conditions, the cement and supplementary cementitious material storage facilities shall be painted with white high solar reflectance
paint and insulated to reduce any temperature rise in the stored cement or supplementary cementitious material.
Cement or supplementary cementitious material supplied in bags shall be closely and neatly stacked, separately to a height not exceeding
12 bags and arranged so that they will not be in contact with the ground, the floor or the walls, and can be used in the order in which they were
delivered to the site.
Cement or supplementary cementitious material supplied in bulk shall be stored separately in waterproof containers so designed as to prevent
any dead spots from forming, and the cement or supplementary cementitious material drawn for use shall be measured by mass.
Cement shall not be kept in storage for longer than 8 weeks without the Engineer's permission, and different brands or types of the same brand
of cement or supplementary cementitious material shall be stored separately.
c) Aggregates
Aggregates of different nominal sizes, sources or types shall be stored separately. Intermixing of different materials and contamination by
foreign matter shall be avoided. Aggregates exposed to a chloride (XS) environment (refer Table A13.4.7-2) shall be covered to protect them
from salt contamination. Sufficient quantity of fine aggregate shall be stockpiled on site and handled in a manner that ensures the thorough
mixing of the various deliveries in order to achieve a stable fineness modulus within the specified limits.
In hot weather concreting conditions, both the coarse- and fine-aggregate stockpiles shall be shaded from the sun. When the ambient
temperature reaches and at all times when it exceeds 30°C, only the coarse aggregate shall be sprayed with water to assist cooling by
evaporation. Water shall be delivered by means of an approved water droplet sprayer system. The Contractor shall ensure adequate drainage
of the aggregate stockpile area.
Where concrete is batched on site, the aggregates shall be stored in bins with a minimum 150 mm thick concrete floor constructed below the
aggregate stockpile to prevent contamination during the storage and handling the aggregate. The floor slab shall be appropriately sloped to
facilitate drainage of the stockpile area. A 3,0 m wide concrete apron slab shall be constructed around the entrance and outer edge of the
aggregate stockpile area and sloped for drainage away from the main stockpile area. The aggregates shall be tipped on the concrete apron
slab to prevent contamination during the process of tipping and hoisting the aggregate.
d) Water
In hot weather concreting conditions, the sides and tops of water tanks for mixing water, including pipework leading to and from tanks, shall be
insulated.

e) Storage capacity
The storage capacity provided and the quantity of material stored, whether cement, supplementary cementitious materials, aggregates,
admixture or water, shall be sufficient to ensure that no interruptions to the progress of the work will be occasioned by any lack of materials.
f) Deteriorated material
Deteriorated or contaminated or otherwise damaged non-conforming material shall not be used in concrete. Such material shall be removed
from the site without delay.

A13.4.6.1 General
Plant used to manufacture, transport, place and test concrete shall be based on proven technology within the industry, and shall be in good
working order. The plant shall be inspected, serviced and calibrated at regular intervals and tested to ensure that the system functions efficiently
and accurately, all to the satisfaction of the Engineer.
The plant and equipment utilised shall be selected to ensure that the peak output required by the approved construction programme can be
achieved and maintained at all times.
A13.4.6.2 Commercially-sourced concrete

Where concrete is supplied by a commercial source outside the direct control of the Engineer, the concrete supplier shall ensure compliance
with the requirements of SANS 50206 (SANS 878), and the Contractor shall have full responsibility to implement process acceptance control
testing in accordance with the specification. Commercial concrete suppliers shall ensure that the plant, measuring, mixing, transport and
associated processes are audited by a recognised independent body in accordance with the following requirements for commercially-sourced
concrete:
a) ISO 9002 (standardisation);
b) ISO 14001 (environmental);
c) ISO 39001 (road transport safety management);
d) OHSAS 18001 (legal compliance); and
e) SANS 50206 (SANS 878), ISO 22965-2 or ISO 9001 (quality management system for concrete production)
The audit shall be valid for a period of no greater than 12 months.
A13.4.6.3 Measuring the materials for the production of mixes

a) Cementitious binder
Where cementitious binder is supplied in standard bags, the bags shall be assumed to contain 50 kg for batching purposes. Cementitious
binder taken from bulk storage containers and from partly used bags shall be batched by mass, accurate to within 2 % of the required mass.
b) Water
The mixing water for each batch shall be measured, either by mass or by volume, accurate to within 2 % of the required quantity. The quantity
of water added to the mix shall be adjusted to make allowance for any moisture in the aggregates.
c) Aggregates
All aggregates for concrete shall be measured separately by mass, except as otherwise provided in this Clause, accurate to within 3 % of the
required quantity.
Aggregates for strength concrete may be volume batched subject to the approval of the Engineer, and to the quantity of cementitious binder
being increased, at the cost of the Contractor, by 25 kg per cubic metre of concrete over and above the quantity which would have been
necessary were the aggregate to have been batched by mass. The concrete mix revision shall be verified to ensure that the total alkali
content (Na2O-equivalent) of concrete shall be limited taking into account the degree of reactivity of aggregates as specified in
Clause A13.4.7.2a).
Batching boxes for volume batching shall be filled without in any way tamping, ramming or consolidating the material (other than that
occurring naturally during the filling of the container), and shall be screeded off level with their topmost edges.
Any adjustment to the volume shall be made by supplementary containers of a suitable size being used. Adjustments to the volume, by the
incomplete filling of batching boxes to marks on their inside faces, will not be permitted.
Fine aggregate shall be tested for bulking at the beginning of and halfway through each concreting shift, and adjustment shall be made to the
batch volume to give the true volume required.
If applicable, the volume batching of aggregate shall be so planned as to use full bags of cementitious binder.
d) Admixture
Admixtures shall generally be supplied in liquid form and accurately dispensed by a mechanical dosing unit, into solution with the mixing water,
except where the admixture cannot be dispersed homogenously into the mixing water, in a manner appropriate to the method of batching, e.g.
dry versus wet batching. Unless extraordinary circumstances dictate otherwise, under no circumstances shall admixtures be dispensed on to
dry mix components. Where such extraordinary circumstances do exist in such cases, other methods of feeding into the concrete mixture shall
be agreed with the Engineer.
All admixtures shall be dispensed in quantities accurate to within 2 % by mass of the desired quantity. The mechanical dosing unit shall be
checked daily for accuracy using a nominal dispensing volume, typically 2 litres, or as recommended by the dosing unit manufacturer or
admixture supplier. At least once a week, the dosing unit shall be checked for accuracy using the full dispensing volume suited to the concrete
mixing procedures employed on site, typically for 6,0 m3 concrete batch mixed by a standard mixing truck and proportionally for other standard
batch volumes.
A13.4.6.4 Mixing
a) General
Mixing the material for concrete shall be conducted by an experienced operator. Unless otherwise authorised, mixing shall be carried out in a
mechanical mass batch-mixer of an approved type which will be capable of producing a uniform distribution of ingredients throughout the
batch.
b) Charging the mixer
The sequence of charging the ingredients shall be subject to approval by the Engineer, and, unless otherwise instructed, the same sequence
of charging the ingredients shall be maintained.
The volume of the mixed material by batch shall not exceed the volume recommended by the manufacturer of the mixer.
Fibres, integral permeability reducing technology, pigments and colouring agents shall be added to the mix in a manner that ensures that they
are uniformly dispersed in the mix.
c) Mixing and discharging
The period of mixing shall be measured from the time when all the materials are in the drum until the commencement of discharge.
The mixing period for the materials shall be at least 90 seconds and may be reduced only if the Engineer is satisfied that the reduced mixing
time will produce concrete with the same strength and uniformity as concrete mixed for minimum 90 seconds. The reduced mixing time,
however, shall be not less than 50 seconds or the manufacturer's recommended mixing time, whichever is the longer. A suitable timing device
shall be attached to the mixer to ensure that the minimum mixing time for the materials has been complied with.
The first batch to be run when starting with a clean mixer, shall contain only 75 % of the required quantity of coarse aggregate to make
provision for coating the mixer drum. Refer Clause A13.4.7.11g) for a similar provision for richer concrete mix placed at horizontal
construction joints.
Discharge shall be so carried out that no segregation of the materials will occur in the mix. The mixer shall be emptied completely before it is
recharged with fresh materials.
d) Maintaining and cleaning the mixer
If the mixer has stopped running for a period in excess of 30 minutes, it shall be thoroughly cleaned out with particular attention being given to
the removal of any build-up of materials in the drum, in the loader, and around the blades or paddles.
Before any concrete is mixed, the inner surfaces of the mixer shall be cleaned and all hardened concrete shall be removed.
Worn or bent blades and paddles shall be replaced.
e) Standby mixer
When sections are cast where it is important for the casting to continue without interruption, a standby mixer shall be held in readiness to run
on 15 minutes notice should the stock mixers break down.

A13.4.7.1 General
Concrete shall comply with the prevention and mitigation requirements for deleterious alkali-silica reaction, limitation on the sulfate content,
limitation on the chloride content, determination of nominal aggregate size and the particular performance requirements for strength concrete,
durable concrete, or prescribed-composition concrete as specified in Clauses A13.4.7.2, A13.4.7.3, A13.4.7.4, A13.4.7.5, A13.4.7.6 and
A13.4.7.7 below. Concrete shall concurrently comply with the desirable properties of fresh and hardened phases as specified in
Clauses A13.4.7.8 and A13.4.7.9.
The Contractor shall be responsible for the performance, in both the fresh and hardened phases, of all concrete irrespective of the variation of
cement or supplementary cementitious material quality between consignments. The actual concrete mix proportions used, as well as any
changes thereto, shall be subject to the Engineer's approval. The Contractor’s quality control system and work scheduling shall also allow for
recognition of the hydration phase of concrete. During that phase adequate measures shall be implemented to assure that freshly placed
concrete is properly protected against any activities which might affect the hydration process.
A13.4.7.2 Prevention and mitigation of deleterious Alkali-Silica Reaction (ASR)

The active proportion of the total alkali content (Na2O-equivalent) of concrete, including contributions from the cement, supplementary
cementitious materials, admixtures and, if required, aggressive environmental conditions, shall be limited taking into account the degree of
reactivity as specified in Clause A13.4.7.2a) below.
a) Laboratory testing and evaluation
(i) Laboratory evaluation of potential alkali reactivity of aggregates using accelerated mortar prism, or mortar bar, method in accordance
with SANS 6245 (with sample test age 14 days) or ASTM C1260 (with sample test age 16 days) shall be conducted.
1. Aggregates with the expansion, at the sample test age, determined as equal to or more than 0,20 % are categorised as ‘rapidly
expansive’, the maximum permitted equivalent sodium oxide (Na2Oeq) of the concrete mixture shall be 2,1 kg per cubic metre of
concrete, except where Witwatersrand Quartzite aggregate is used the maximum permitted equivalent sodium oxide (Na 2Oeq) shall
be 2,0 kg per cubic metre of concrete;
2. Aggregates with the expansion, at the sample test age, determined as equal to or more than 0,10 % but less than 0,20 % are
categorised as ‘slowly expansive’, the maximum permitted equivalent sodium oxide (Na2Oeq) of the concrete mixture shall be
2,8 kg per cubic metre of concrete; or

3. Aggregates with the expansion, at the sample test age, determined as less than 0,10 % are categorised as ‘innocuous’, the
maximum permitted equivalent sodium oxide (Na2Oeq) of the concrete mixture shall be 4,0 kg per cubic metre of concrete.
(ii) Where untested sources of cement or supplementary cementitious materials are proposed, laboratory evaluation of potential alkali
reactivity of cementitious binder-aggregate combinations using the concrete prism method in accordance with ASTM C227 shall be
conducted.
1. Cementitious binder-aggregate combinations with the expansion of more than 0,05 % at 52 weeks shall be considered a deleteriously
expansive combination and shall be rejected; or
2. The maximum permitted equivalent sodium oxide (Na2Oeq) of the concrete mixture shall be 2,4 kg per cubic metre of concrete, until
the aggregate has been classified by laboratory evaluation, unless the aggregate can be geologically linked with a previous SANS
6245 or ASTM C1260 evaluation and classified according to Clauses A13.4.7.2a) (i), (ii) or (iii).
(iii) Where potentially alkali reactive aggregates are used in a marine (XS) environment (refer Table A13.4.7-2), nominal aggressive
environmental contributions to the active alkali content of the concrete mixture under investigation shall be 0,01, 0,02 or 0,03 % of the
total binder content for XS1, XS2 or XS3 environments respectively.
b) Prevention and mitigation measures
ASR prevention measures may include the substitution of the cement source, supplementary cementitious material or aggregate types. ASR
mitigation measures shall include the redesign of the cementitious binder composition to incorporate ameliorating measures suggested in
specialist literature, such as Fulton’s Concrete Technology.
A13.4.7.3 Limitations on the sulfate content

The total acid soluble sulfate content of the concrete mix, expressed as SO3, shall not exceed 4 % by mass of the cementitious binder content
in the mix. The sulfate content shall be calculated as the cumulative total from the various constituents of the mix according to SANS 5213.
A13.4.7.4 Limitation on the chloride content

The total acid soluble chloride content of reinforced concrete shall not exceed 0,35 % by mass of the cementitious binder content of the mix
where there is no further possibility of additional chloride contamination. For prestressed concrete, in chloride (XS) environments or where
chloride contamination is a possibility, the total acid soluble chloride content shall not exceed 0,20 % by mass of the cementitious binder for
all intended structural uses. The chloride content shall be calculated as the cumulative total from the various constituents of the mix.
A13.4.7.5 Determination of nominal aggregate size

The aggregate sizes shall be selected in accordance with SANS 1083 and shall be selected after giving due consideration to the specified
nominal cover, reinforcement spacing and layout and particular congested areas of reinforcement, for example around prestressing
anchorages, etc. The Contractor may propose amendment of the nominal aggregate size to facilitate the selected aggregate properties or the
agreed construction method. Amendment of aggregate size from that specified on the drawings shall be subject to the approval of the Engineer
in writing and shall conform to the requirements of Table A13.4.7-1 nominal sizes of aggregates for concrete.
Table A13.4.7-1: Nominal sizes of aggregates for concrete complying with SANS 3001-AG1
Coarse aggregate Fine aggregate
Nominal sieve aperture size, Nominal sieve aperture size,
mm mm
63 5
50 2
37,5 1
28 0,600
20 0,425
14 0,300
10 0,150
7,1 0,075
A13.4.7.6 Strength (Class C) concrete

The compressive strength class is indicated by the designated concrete code C, the characteristic 28-day cylinder strength in MPa, the
characteristic 28-day cube compressive strength in MPa and the nominal size of coarse aggregate in the mix. For example, C28/35-20 means
strength concrete class with a characteristic cylinder strength of 28 MPa at 28 days or characteristic cube compressive strength of 35 MPa at
28 days and a nominal size coarse aggregate of 20 mm.
Typical applications of strength concrete may include:
(i) in benign exposure environments (X0) where there is no risk of corrosion or attack;
(ii) where relatively short service life (typically 25 years) is anticipated;
(iii) temporary structures; or
(iv) as specified on the drawings where compressive strength is the governing criteria.
A13.4.7.7 Durable (Class D) concrete

Durable concrete shall be utilised for structures requiring extended service life of 100 years and in typical environments that require a minimum
of 80 % of the service life to be free from the risk of corrosion.

The class of concrete is indicated by the designated durable concrete code D, the characteristic28-day cylinder strength in MPa, the
characteristic 28-day cube strength in MPa, the nominal size of coarse aggregate in the mix, and the environmental class designation. for
example D35/45-20-XC4 means durable concrete class with a characteristic cylinder compressive strength of 35 MPa after 28 days or
characteristic cube compressive strength of 45 MPa after 28 days, a nominal size coarse aggregate of 20 mm, and a corresponding set of
particular durability index values suitable for an XC4 environment.
The environmental classes as determined by the design engineer, suitable for the general South African environments are listed in Table
A13.4.7-2.
Table A13.4.7-2: Environmental Classes
Environmental Limited description
Class
X0 No corrosion risk
Corrosion induced by carbonation
XC1a External concrete exposed to low humidity (<50%

RH) and sheltered from moisture; arid areas;
interior concrete
XC1b Permanently wet or saturated-damp
XC2 Wet, rarely dry
XC3 External concrete exposed to moderate humidity

(50-85% RH) and sheltered from rain in non-arid
areas
XC4 External concrete exposed to rain or condensation,
or alternately wet and dry conditions
Corrosion induced by seawater, sea spray and saline groundwater
XS1 Exposed to airborne salt but not in direct contact

with seawater or inland saline water
XS2a Permanently submerged in sea (or saline) water
XS2b XS2a with abrasion
XS3a Tidal, splash and spray zones
XS3b XS3a with abrasion
Specialist literature, such as BRE Special Digest 1: ‘Concrete in aggressive ground’, should be consulted where sulfate-bearing water,
aggressive groundwater, aggressive chemical environments or aggressive environments not classified in Table A13.4.7-2 are encountered.
Class D concrete mix shall meet the following criteria:
(i) the specified 28-day characteristic cylinder or cube compressive strength;
(ii) the specified 28-day nominal oxygen permeability index;
(iii) the specified 28-day nominal chloride conductivity value; or
(iv) a characteristic 28-day cylinder or cube compressive strength corresponding to the maximum water: cementitious binder ratio for
chloride (XS) environments.
Durable concrete for environments where corrosion induced by carbonation presents the governing risk, the desirable properties shall conform
to Table A13.4.7-3 for 100 year service life.
Table A13.4.7-3: Nominal Durability Index and cover values for 100 year service life in typical carbonating environments
Environmental Cover (mm), OPI (log
class as specified scale)
For 100 year service life
XC1a, and 40 9,15
XC1b 50 9,00
60 9,00
XC2 40 9,40
50 9,10
60 9,00
XC3 40 9,65
50 9,35
60 9,05
XC4 40 9,85
50 9,55
60 9,30

Durable concrete for environments where corrosion induced by chlorides in water or in the atmosphere presents the governing risk, the
desirable properties shall conform to Table A13.4.7-4 for 100 year service life.
Table A13.4.7-4: Nominal Durability Index and cover values for 100 year service life in typical chloride environments
Environmental Cover (mm), as Chloride Conductivity (mS/cm)
class specified
Typical Cementitious Binder System3
Fly ash Blastfurnace slag Corex slag Silica fume
(30 %) (50 %) (50 %) (10 %)
For 100 year service life
XS1 40 1,20 1,30 1,602 n/a1
50 1,852 1,952 2,202 0,40
60 2,152 2,352 2,752 0,65
XS2a 50 0,85 1,00 1,20 n/a1
2 2
60 1,25 1,45 1,70 n/a1
XS2b 60 1,10 1,30 1,552 n/a1
XS3a 50 0,65 0,80 0,95 n/a1
60 0,95 1,10 1,40 n/a1
XS3b 60 0,85 1,00 1,30 n/a1
Note: 1) n/a means cementitious binder system is not suitable for the indicated purpose.
2) Maximum water: cementitious binder ratio for all binder systems shall be maximum 0,550.
A13.4.7.8 Prescribed-Composition (Class P) concrete

Where performance of concrete is influenced by mix composition limitations placed on strength class concrete in the Contract Documentation,
the concrete shall be referred to as prescribed-composition concrete and designated by the prefix "P”. This may include the specification of a
particular aggregate type or source, for example dolomitic aggregate, for incorporation into the concrete mix. For example, P32/40-20 means
prescribed-composition concrete class with a characteristic cylinder strength of 32 MPa at 28 days or characteristic cube compressive strength
of 40 MPa at 28 days and a nominal size coarse aggregate of 20 mm. For Class P concrete, the characteristic strength of the mix shall be
based on the higher of the following values:
(i) the specified 28-day characteristic cylinder or cube compressive strength;
(ii) a characteristic 28-day cylinder or cube compressive strength corresponding to the maximum water: cementitious binder ratio;
(iii) a characteristic 28-day cylinder or cube compressive strength corresponding to the minimum cementitious binder content; or
(iv) a 28-day characteristic cylinder or cube compressive strength corresponding to the maximum water content.
A13.4.7.9 Properties of fresh concrete

a) Bleeding and settlement
The concrete mix shall be so proportioned with suitable materials that bleeding is not excessive, is limited to maximum 3 % and that
settlement is minimised. Bleeding shall be determined in accordance with ASTM C232, or where the effect of the admixture dose is reported,
in accordance with EN 480-4. Excessive bleeding and settlement that may adversely affect the structural performance or durability of
concrete through the formation of voids under coarse aggregate particles and the reinforcement or by plastic settlement cracking, shall at
least be counteracted by strictly monitored revibration and recompaction efforts (refer Clause A13.4.7.11d)(i)) during concreting activities or
approved revision of the concrete mix design.
b) Air content
Where required, the air content of fresh concrete mix shall be determined in accordance with SANS 3001-CO1-8.
c) Consistence and workability
The consistence of concrete in the fresh state shall be classified in accordance with the desirable consistence classes described in Tables
A13.4.7-5, A13.4.7-6, A13.4.7-7, A13.4.7-8 or A13.4.7-9. Self-compacting concrete shall comply only with Table A13.4.7-9 and
Clause A13.4.7.8c)(i). Pumped concrete shall comply with Clause A13.4.7.8c)(ii). The Contractor shall be responsible to select the consistence
class appropriate for his construction method and shall record the selection in the mix design before the commencement of concreting activities.
Slump tests shall be conducted in accordance with SANS 3001-CO1-3.
Table A13.4.7-5: Slump classes and values
Slump (mm) determined in
Consistence Class
accordance with SANS 3001-CO1-3
ZA-S1 30 ± 20
ZA-S2 75 ± 20
ZA-S3 125 ± 25
ZA-S4 180 ± 30

Where slump may be less than 10 mm and Vebe time is the desirable measure of consistence, Vebe tests shall be conducted in accordance
with SANS 3001-CO1-4.
Table A13.4.7-6: Vebe time classes and values
Vebe time (s) determined in
Consistence Class
ZA-V1 5 to 10
ZA-V2 11 to 20
ZA-V3 21 to 30
Where the degree of compaction is the desirable measure of consistence, the compacting factor shall be determined in accordance with
SANS 3001-CO1-5 (EN 12350-4).
Table A13.4.7-7: Degree of compaction classes and values
Compaction factor determined in
Consistence Class accordance with SANS 3001-CO1-5
(EN 12350-4)
ZA-C1 0,80 or less
ZA-C2 0,81 to 0,89
ZA-C3 0,90 or greater
Where slump may exceed 150 mm and flow is the desirable measure of consistence, flow shall be conducted in accordance with SANS 3001-
CO1-6.
Table A13.4.7-8: Flow classes and values
Flow diameter (mm) determined in
Consistence Class
ZA-F1 500 to 545
ZA-F2 550 to 595
ZA-F3 600 to 650
Where high workability concrete is used and the slump flow is the desirable measure of consistence, slump flow shall be conducted in
accordance with SANS 3001-CO1-9 (EN 12350-8).
Table A13.4.7-9: Slump flow classes and values
Slump flow diameter (mm)
Consistence Classes determined in accordance with
SANS 3001-CO1-9 (EN 12350-8)
ZA-SF1 550 to 650
ZA-SF2 660 to 750
ZA-SF3 760 to 850
(i) Additional properties of self-compacting concrete

The additional properties of self-compacting concrete, in particular viscosity, passing resistance and sieve segregation, are classified and
described in Tables A13.4.7-10, A13.4.7-11, A13.4.7-12, A13.4.7-13 or A13.4.7-14 below.
Viscosity shall be assessed using the time to reach 500 mm flow, T500, determined in accordance with SANS 3001-CO1-9 (EN 12350-8) or the
V-funnel flow time, Tv, determined in accordance with SANS 3001-CO1-10 (EN 12350-9).

Table A13.4.7-10: T500 Viscosity classes and values
500 mm Flow time T500 (s)
Viscosity Class determined in accordance with
SANS 3001-CO1-9 (EN 12350-8)
ZA-VS1 Less than 2,0
ZA-VS2 2,0 or greater
Table A13.4.7-11: Tv Viscosity classes and values

V-funnel flow time Tv (s) determined
Viscosity Class in accordance with SANS 3001-
CO1-10 (EN 12350-9)
ZA-VF1 Less than 9,0
ZA-VF2 9,0 to 25,0
Passing resistance shall be assessed using either the L-box determined in accordance with SANS 3001-CO1-11 (EN 12350-10) or J-ring tests
determined in accordance with SANS 3001-CO1-13 (EN 12350-12).
Table A13.4.7-12: L-Box passing resistance classes and values

L-box ratio determined in
Passing Resistance Class accordance with SANS 3001-CO1-11
(EN 12350-10)
ZA-PL1 At least 0,80 with 2 rebars
ZA-PL2 At least 0,80 with 3 rebars
Table A13.4.7-13: J-Ring passing resistance classes and values

J-ring step (mm) determined in
Passing Resistance Class accordance with SANS 3001-CO1-13
(EN 12350-12)
ZA-PJ1 Maximum 10,0 with 12 rebars
ZA-PJ2 Maximum 10,0 with 16 rebars
Sieving segregation resistance shall be determined in accordance with SANS 3001-CO1-12 (EN 12350-11).
Table A13.4.7-14: Sieve segregation resistance classes and values
Segregation portion (percent)
Segregation Resistance Class determined in accordance with
SANS 3001-CO1-12 (EN 12350-11)
ZA-SR1 Maximum 20
ZA-SR2 Maximum 15
(ii) Additional properties of pumped concrete

Where concrete is transported and placed by pumping, the concrete mix to be pumped shall be so designed that:
1. the consistence and workability shall conform to the range of slump values stipulated in Table A13.4.7-5.
2. the maximum slump shall be 210 mm.
3. graded aggregate, controlled fines content and suitable admixtures shall be used, wherever necessary, with a view to improving the
pumpability and cohesiveness of the mix.
4. the initial drying shrinkage capacity of pumped concrete determined in accordance with SANS 3001-CO2-7 shall not exceed 0,040 % for
prestressed members or 0,045 % for reinforced members.
A13.4.7.10 Properties of hardened concrete

a) Compressive strength
For the purposes of determining compressive strength, the characteristic cylinder strength shall be determined using 150 mm diameter, 300 mm
high cylinder or the characteristic cube compressive strength shall be determined using 150 mm cubes and all test specimens shall be prepared
strictly in accordance with SANS 3001-CO2-2 and tested in accordance with SANS 3001-CO2-3 at 28 days. All concrete shall be categorised in
the compressive strength classes, using both a characteristic cylinder strength and characteristic cube strength, as shown in Table A13.4.7-15.

Table A13.4.7-15: Compressive strength classes for normal-weight aggregates
Compressive Minimum Minimum
strength class characteristic characteristic cube
cylinder strength, strength, MPa
MPa
C12/15 12 15
C16/20 16 20
C20/25 20 25
C25/30 25 30
C28/35 28 35
C32/40 32 40
C35/45 35 45
C40/50 40 50
C45/55 45 55
C50/60 50 60
C54/65 54 65
C57/70 57 70
C60/75 60 75
C65/80 65 80
C70/85 70 85
C75/90 75 90
C80/95 80 95
C85/100 85 100
C90/105 90 105
C100/115 100 115
For particular uses, it may be necessary to specify the compressive strength at ages earlier or later than 28 days, for example massive structural
elements, or after storage under special conditions, for example heat treatment. In assessing the strength, other sizes of mould and other curing
regimes may be used provided the relationship to those standardised has been established and documented and subject to the approval of the
Engineer.
b) Tensile splitting strength
The tensile splitting strength shall be determined at 28 days in accordance with SANS 3001-CO2-6.
c) Flexural strength
The flexural strength shall be determined from beam specimens prepared in accordance with SANS 3001-CO2-3 and tested at 28 days in
accordance with SANS 3001-CO2-5.
d) Energy absorption capacity of fibre reinforced concrete
The minimum energy absorption capacity shall be specified on the drawings. The energy absorption capacity shall be determined from a slab
specimen, tested at 28 days in accordance with EN 14488-5, save that the fibre reinforced concrete shall be cast into the formwork using
conventional concreting techniques. The energy absorption capacity shall conform to the specified energy adsorption class defined in Table
A13.4.7-16.
Table A13.4.7-16: Energy absorption classes and values
Energy absorption class Energy adsorption for deflection
up to 25mm (J)
E500 500 to 690
E700 700 to 990
E1000 1000 and greater
e) Concrete durability index testing

Test specimens shall be prepared in accordance with SANS 3001-CO3-1 from test panels. Test panels shall have dimensions of 600 mm high
by 400 mm wide and 150 mm thick and be placed, constructed and cured in the same manner as the Contractor utilised for the representative
structural element. Test samples shall be obtained perpendicular to the casting direction between 26 and 35 days after casting. A maximum of
six test specimens can be cored from the formed face of each test panel, excluding the outer 100 mm along the perimeter of the test panel.
Additional test panels may be required in instances where more than six test specimens are required.

The oxygen permeability test shall be conducted in accordance with SANS 3001-CO3-2. The chloride conductivity test shall be conducted in
accordance with SANS 3001-CO3-3. If required, the water sorptivity test shall be conducted in accordance with Clause A20.1.6.5.1f) of Chapter
20 (or SANS 3001-CO3-4).
f) Verification of concrete cover depth
All reinforced and prestressed concrete elements shall be subject to the verification of concrete cover over reinforcing in the two following ways.
(i) Visual inspection prior to concrete placement
Prior to the placement of concrete, all elements shall be inspected for concrete cover. The minimum cover shall be as specified
on the drawings, and spacers shall be manufactures accordingly. The placing and spacing of spacers shall be carefully controlled.
For the visual inspection, no reduction in cover from the specification will be permitted and the Contractor shall ensure that he
manages his construction tolerances to achieve the specified cover.
The maximum cover shall be 10 mm greater than specified for elements less than 500 mm thick, 15 mm greater than specified for
elements greater than or equal to 500 mm thick, or 25 mm greater than specified for elements cast against ground.
(ii) Post-casting verification of concrete cover depth
All reinforced, prestressed and precast concrete shall be subject to the verification of cover depth. The cover survey shall be
conducted using the manual, grid or block survey method and cover metre devices that comply with BS 1881 Part 204 or
ACI 228. Cover surveys shall be conducted after removal of the formwork, including the repair of form tie holes, or after the
completion of the curing period.
Cover surveys shall be conducted for all element types, including both formed and unformed surfaces, at a minimum sampling
ratio of 2 % of surface area of concrete elements placed. The Engineer shall select the particular structural elements and specific
areas for cover verification. Particular elements that will require extensive cover depth verification shall include all parapet
surfaces, including parapet beam and aesthetic detail recesses, all buried surfaces of abutments, piers, wingwalls and walls, up
to 1,5 m above the design fill lines prior to the commencement of backfilling operations.
Cover analysis should be conducted in accordance with Clause A20.1.5.1h) of Chapter 20. Should another cover survey method
be proposed, for example linear or quick scan method, a calibration procedure shall be conducted strictly according to
Clause A20.1.5.1h) of Chapter 20 and shall be submitted to the Engineer for approval prior to use.
g) Drying shrinkage
The drying-shrinkage of concrete specimens determined in accordance with SANS 3001-CO2-7 shall not exceed 0,040 % for prestressed
concrete or 0,045 % for reinforced and plain concrete;
A13.4.7.11 Protection of Concrete from Adverse Environmental Conditions

a) General
Precautions shall be taken as needed to prevent concrete from damage due to adverse weather or other environmental conditions before or
during the placing and curing operations. The fresh phase of concrete shall be protected from rain and hot or cold weather, and once placed,
shall be protected from vibration, movement and impact that could disrupt the concrete hydration phase and adversely affect its bond to the
reinforcement. Hardened phase concrete shall also be protected from mechanical damage and contamination until curing has been
completed.
The temperature of the concrete mixture immediately before placement shall be between 10°C and 30°C, except as otherwise provided
herein.
b) Rain protection
Concrete shall not commence or shall be stopped unless adequate protection is provided to prevent damage to the exposed surface.
c) Hot weather protection
When the ambient temperature exceeds 30°C, the Contractor shall ensure that the temperature of the concrete mixture is maintained within
the stipulated limits. The formwork, reinforcing steel, structural steel components and other surfaces that will come into contact with the
concrete mix shall be cooled to below 30°C by means of a water spray or other methods approved by the Engineer.
The temperature of the concrete mixture at the time of placement shall not exceed 30°C. The Contractor shall take the necessary measures
to control the temperature of the mixture ingredients by preventative measures which may include:
(i) Insulating cement and supplementary cementitious material silos and water bulk storage containers;
(ii) Spraying of coarse aggregate stockpiles with water to promote cooling down by evaporation;
(iii) Shading the aggregate stockpiles;
(iv) Shading the area where concreting is to be carried out;
(v) Cooling the external surface of the mixer truck drum which may be lagged with hessian and kept damp, or with running water during
mixing and again prior to discharge on site;
(vi) Cooling the aggregates or water by refrigeration or replacing a portion of all of the mix water with ice that is flaked or crushed to the
extent that the ice will completely melt during mixing of the concrete; or
(vii) Liquid nitrogen injection directly into the mix.
d) Cold weather protection
Unless suitable protection measures are in places, concrete shall not be placed during falling temperatures when the ambient temperature
falls below 7°C and shall only be placed during rising temperatures when the ambient temperature is above 5°C. When concrete is placed at
ambient temperatures below 5°C the concrete temperature shall not be below 10°C, for which purpose heating of the water, heating of the
aggregate or the concrete mixture shall be permitted. The Contractor shall make all the necessary arrangements for heating the materials and
the methods used shall heat the materials uniformly. Neither the aggregates nor the water shall be heated to over 65°C. Heated water and
aggregate shall first be mixed and the cementitious binder shall then be added only while the temperature of the mix is below 30°C.

The temperature of placed concrete shall not be allowed to fall below 5°C until the concrete has attained the compressive cube strength of at
least 5 MPa, determined from cube samples stored under the same conditions as the structural member, and the Contractor shall be
responsible for all protective measures necessary to this end. If external heating is employed, the heat shall be applied and withdrawn
gradually and uniformly so that no part of the concrete surface is heated to more than 35°C or caused to change temperature by more than
20°C in 8 hours. All concrete damaged by frost or by the formation of ice in the concrete shall be removed and replaced by the Contractor at
his own expense.
e) Particular requirements for slabs, bridge decks and unformed surfaces
When typical slab elements are cast, in particular the ambient temperature, the relative humidity, concrete temperature and wind speed shall
be actively monitored to ensure that the rate of evaporation is minimised and at all times limited to maximum 1 kg per square metre per hour
in accordance with ACI 305R or the Concrete Society of Southern Africa technical report on Concrete Curing (November 1991, ISBN 0-620-
16248-1). During periods of low humidity, wind or high temperatures and prior to the application of the curing measures, unformed concrete
being placed and finished, shall be protected from damage due to rapid evaporation. Such protection shall be adequate to prevent plastic
shrinkage cracking, premature crusting of the surface or an increase in drying shrinkage cracking. Such protection shall be provided by:
(i) Raising the humidity of the surrounding air with fog sprayers operated upwind of the slab;
(ii) The use of wind-breaks and sun-shades;
(iii) Additionally reducing the temperature of the concrete; or
(iv) Scheduling placement during cooler parts of the day or nights.
(v) Application of liquid evaporation retarders.
f) Concrete exposed to aggressive water or soil
Where increased risk of damage due to early age exposure of concrete surfaces to aggressive water or soil is anticipated, additional
precautionary measures shall be required. In addition to measures contained in specialist literature such as BRE Special Digest 1: ‘Concrete
in aggressive ground’, the protective measure shall also include:
(i) No construction joints shall be permitted for concrete elements in permanent contact with the aggressive water or soil;
(ii) Formwork, and where necessary drainage provisions in excavations, shall be continuously maintained for at least 96 hours after casting;
(iii) Except for the repair of any isolated areas of grout loss and the plugging of form tie holes, the original formed surfaces shall be left
undisturbed; or
(iv) All external surfaces permanently exposed to aggressive water or soil shall be protected with a waterproofing system or protective
coating as specified on the drawings.
g) Thermal gradients in concrete elements
For all concrete pours, the maximum temperature difference between any two points in the pour shall be limited to 22°C and the maximum
temperature shall be 70°C. Where these values may be exceeded, specialist literature such as The Highways Agency (UK) BD 28/87: ‘Early
thermal cracking of concrete’, shall be consulted.
h) Precautionary measures for using sliding formwork
During sliding operations in cold weather, the water only, or the water and the aggregate, shall be heated to ensure that the concrete
temperature will not drop below 10°C until it has attained a compressive strength of 5 MPa, determined from cube samples stored under the
same conditions as the structural member.
During cold weather the rate of sliding shall be suitably decreased to ensure sufficient strength in the concrete which leaves the tail of the
formwork.
A13.4.7.12 Placing and Compaction

a) General
Concrete shall be transported and placed in a manner that will prevent segregation or loss of constituent materials or the contamination of the
concrete. Immediately prior to discharge of the concrete transported by mixer trucks, the drum shall be rotated at the highest revolution per
minute for a minimum period of 4 minutes per typical 6 cubic metre volume and proportionally for other mixing volumes.
Concrete shall not be placed in any part of the works until the Engineer's approval has been given. If concreting is not started within 24 hours
of approval having been given, approval shall again be obtained from the Engineer.
Concreting operations shall be carried out only during daylight hours unless proper lighting arrangements have been made subject to the
approval of the Engineer, and the lights are in good working order by noon. Workmen shall not be allowed to work double shifts and the
Contractor shall provide a fresh team for night shifts.
Placing and compacting the concrete shall at all times be under the direct supervision of an experienced concrete supervisor. In order to
accept each concrete delivery, the official batch ticket shall be examined and assessed for compliance, the consistence or workability
assessed, and the temperature of the concrete at delivery recorded as part of the Contractor’s process control obligations. Concrete delivered
with temperatures or with consistence and workability outside the particular range as stipulated in Clauses A13.4.7.8c) and A13.4.7.11, shall
be rejected.
Once the casting of concrete has begun, it shall be carried out in a continuous process between construction joints. Concrete shall be placed
within 60 minutes from the start of mixing. This time may be extended by the Engineer where a retarding admixture has been used. All
excavations and other contact surfaces of an absorbent nature such as timber formwork shall be damp but no standing water shall be
permitted to remain on these surfaces. The formwork shall be clean on the inside.
b) Placing
Whenever possible, concrete shall be deposited vertically into its final position. Subject to the approval of method statements for particular
concrete pour operations, the maximum height concrete will be permitted to free-fall shall be limited to 3,0 m. Unless a specific method
statement has been approved by the Engineer the pour will be at the Contractor’s risk. Preventative measures to avoid segregation shall be
employed whenever deemed necessary, particularly for concrete pours exceeding 2,4 m high. Where chutes are used, their length and slope
shall be such as not to cause segregation, and suitable spouts and baffles shall be provided at the lower end to minimise segregation. The
displacement of concrete by vibration instead of by direct placing shall be done only when approved by the Engineer.

Care shall be taken when casting bridge decks of a substantial thickness to avoid layering of the concrete, and the entire thickness shall be
placed in one pass, except when permanent void formers are used. Fresh concrete shall not be placed against concrete which has been in
position for more than 60 minutes unless a construction joint has been formed or unless a set-retarding additive has been used in the
concrete. Particular care shall be exercised when incorporating permanent void formers within a concrete section, where additional measures
may be required, to restrain and comprehensively ensure that permanent void formers are not displaced during concrete placement.
The pumping of concrete shall be subject to approval by the Engineer. Aluminium pipes shall not be used for this purpose.
In plain concrete with a thickness greater than 350 mm, plums and boulders may, if approved, be included to displace concrete for up to 20 %
of the total volume, provided that the strict compliance with Clause A13.4.5.2d) is maintained.
c) Placing under water
Placing under water shall be allowed only in exceptional circumstances where it is unfeasible to dewater the location before the concrete is
placed. No concrete shall be placed in running water.
Underwater concrete shall be placed by means of tremies or other approved methods. Full details of the method proposed by the Contractor
shall be submitted in advance for approval. Placing by skip or pipeline will also be considered in certain circumstances.
During concreting by tremie, the pipe shall be kept filled with concrete at all times to prevent air and water from entering the tremie. When the
tremie is charged, an approved sliding plug shall be used. Once concreting has begun by tremie, the discharge end of the tremie shall be kept
well below the surface of the concrete. Should this seal be broken, the tremie shall be lifted and plugged before concreting is recommenced.
Distribution of concrete by lateral movement of the tremie will not be permitted.
The concrete mix to be placed underwater shall be specially designed and approved for this purpose to ensure good flowability, plasticity and
cohesion. Increased sand and cementitious contents over those of normal mixes and viscosity-modifying, anti-washout admixtures shall be
required. Sillica fume may also be incorporated into the mix to improve cohesion.
d) Compaction
Concrete shall be fully compacted by approved means during and immediately after placing. It shall be thoroughly worked against the
formwork, around reinforcement bars, tendons, ducts and embedded fittings and into corners to form a solid mass free from voids.
The concrete shall be free from honeycombing and planes of weakness, and successive layers of the same lift shall be thoroughly bonded
together.
All concrete, except concrete placed under water, self-compacting concrete and unless otherwise permitted by the Engineer, shall be
compacted by means of mechanical vibration immediately after placement. Internal vibrators shall be capable of operating at a frequency of
more than 10,000 cycles per minute and, where permitted, external vibrators at a frequency of more than 3,000 cycles per minute. Sufficient
standby vibrators shall be kept available in case of breakdowns.
Vibration shall be applied by experienced workmen, for sufficient duration and intensity to thoroughly compact the concrete, but over-vibration
resulting in segregation, surface water and leakage shall be avoided. Internal vibrators shall be inserted and withdrawn out of the concrete
slowly. Application of vibrators shall be at points uniformly spaced and not further apart than 8 times the vibrator diameter. Internal vibrators
shall not be used to transport concrete in the formwork. Vibration shall be supplemented by such spading as is necessary to assist the uniform
placement and compaction of the concrete. Contact with reinforcement and formwork shall, in so far as is practicable, be avoided when internal
vibrators are used. Concrete shall not be subjected to disturbance by vibration within the hydration phase of 4 to 24 hours of it having been
compacted.
Whenever vibration is applied externally, the design of the formwork and positioning of vibrators shall be such as to ensure efficient compaction
and avoidance of surface blemishes.
Special attention shall be given to the compaction of concrete in the anchorage zones and behind the anchor plates and in all places where high
concentrations of reinforcing steel or cables occur. Vibration shall be supplemented by tamping with suitable rods and spades as is necessary
to ensure dense concrete along formwork surfaces and in corners and locations where internal vibrators cannot reliably reach.
Where the placing and compaction of concrete is difficult, self-compacting concrete or an alternative mix containing smaller sized aggregate
may be used and only after a revised mix containing such aggregate has been designed, tested and approved by the Engineer.
(i) Revibration or recompaction
The detrimental effects of excessive bleeding and settlement shall be counteracted by the revibration or recompaction technique.
The revibration or recompaction of the concrete shall be conducted at a time as long as possible (typically 1 to 2 hours) after initial
compaction but while the concrete retains sufficient workability to respond plastically to the compactive effort. It should not be
attempted once the hardened phase of the concrete has commenced. Revibration is usually achieved in practice through the use
of internal vibrators but surface vibrator can also be used. Particular application of this technique will normally be required in the
following typical applications:
1. the upper zones of walls and columns;
2. any formed shapes that have abrupt changes in cross section, such as T-beams, I-beams and coffered slabs;
3. any elements that have horizontal reinforcement placed near the top surface of the concrete member;
4. water-tight structures; and
5. structures constructed from durable (class D) concrete or exposed to aggressive environmental conditions.
e) Requirements in respect of sliding formwork
Where sliding formwork is used, the following additional requirements shall apply:
(i) The Contractor shall take all the necessary measures to ensure the continuity of operations. All the necessary lighting and standby
equipment for mixing, hoisting, placing and compacting shall be provided and all the materials required for completing each structure
shall be ready on the site before casting commences;
(ii) For vertical sliding, concrete shall be cast in uniform layers in the formwork so that the level of the top surface of the concrete differs
by no more than 250 mm between any two points in the formwork. In addition, the top level of the concrete shall never be so low down
in the formwork as will cause structural instability in the formwork. The working platform shall be kept clean and no concrete which has
dried out in part may be swept into the formwork;
The concrete shall be compacted during and immediately after placing. Successive layers must be knitted together, i.e. the previous layer must
distribute to minimise lifting cracks and to ensure integrity. To ensure the proper bonding of successive layers, not more than 60 minutes shall
elapse between the placing of successive layers except where an approved admixture has been applied or fine mist sprayers used to avoid
drying out of the previous layer, in which case the delay may be amended as approved by the Engineer in consideration of such circumstances;
and
(iii) The slump of concrete may be up to 210 mm should the approved method of sliding so require.
f) No fines concrete (Class NF)
(i) General
No-fines concrete shall be classified by the prefix “NF” and the size of the aggregate to be used. Class NF-20 means a no-fines
concrete with a 20 mm nominal aggregate size. No fines concrete may be cast in place or precast.
(ii) Materials
Cement shall comply with the requirements of Clause A13.4.5.1a) and site-blending with supplementary cementitious materials
shall not be permitted.
Each nominal size of aggregate shall be a single-sized aggregate complying with the requirements of Clause A13.4.5.2.
Water shall comply with the requirements of Clause A13.4.5.3.
(iii) Classes of no-fines concrete
The classes of no-fines concrete and volume of aggregate per 50 kg cement for each class of concrete shall be as indicated in
Table A13.4.7-17.
Table A13.4.7-17: Volume of aggregate in class NF concrete
Class Aggregate per 50 kg cement
NF-37,5 0,33 m3
NF-28 0,32 m3
NF-20 0,30 m3
NF-14 0,27 m3
Compressive strength, determined from 150 mm cube samples, shall be minimum 4,0 MPa at 28 days.
(iv) Batching and mixing
Cement shall be measured by mass or in full bags of 50 kg each and aggregate shall be measured by volumes in approved
measuring boxes or barrows.
The aggregate shall be moist or wetted before the cement is added.
The quantity of water added shall be just sufficient to form a smooth grout which will adhere to, and completely coat, every
particle of aggregate, and which is just wet enough to ensure that, at points of contact of aggregate, the grout will run together
to form a small fillet to bond the aggregate together. The mix shall contain no more than 20 litres of water for every 50 kg of
cement.
Mixing shall be done in an approved batch-type mechanical mixer, but small quantities may be hand mixed.
(v) Placing
No-fines concrete shall be placed in accordance with the procedure approved by the Engineer. If cast in situ, it shall be placed
in its final position, and if precast it shall be placed in the mould, within 30 minutes of mixing.
The no-fines concrete shall be worked sufficiently to ensure that it completely fills the space to be concreted and that adjacent
aggregate particles are in contact with one another. Excessive tamping or ramming shall be avoided and under no
circumstances may the no-fines concrete be vibrated. Due care must be taken to ensure that any geosynthetic filter fabric and
drainage provisions are not contaminated.
The Contractor shall be responsible to ensure the permeability of the no fines concrete. The Engineer may request to
Contractor to demonstrate the permeability of no fines concrete in place and any portion deemed to be of insufficient
permeability shall be broken out and replaced at the Contractor’s expense.
(vi) Curing and surface protection
All no-fines concrete shall be protected from the elements and loss of moisture. Protection against loss of moisture shall be
accomplished in one or more of the following ways:
1) retaining formwork in place;
2) covering exposed surfaces with sacking or other approved absorbent material kept continuously wet; or
3) covering exposed surfaces with plastic sheeting.
No fines placed during cold weather shall be adequately protected against frost for at least 3 days.
g) Construction joints
(i) General
Concreting shall be carried out continuously up to the construction joints shown on the working drawings or as approved by the
Engineer, except that if, because of an emergency, such as breakdown of the mixing plant or the occurrence of adverse
environmental conditions, concreting has to be interrupted, a construction joint shall be formed at the place of stoppage and in
the manner which will least impair the durability, appearance, and proper functioning of the concrete. If directed by the
Engineer, additional reinforcing steel dowels shall be placed across the emergency construction joint and the additional steel
shall be furnished and placed at the Contractor’s expense.
Unless otherwise shown on the drawings, the exact position of horizontal construction joints shall be marked on the formwork.
The external face, for the specified cover depth, of fresh concrete at horizontal construction joints shall be wood floated
sufficiently to thoroughly compact the surface and to form a neat regular straight line for aesthetic reasons. The remaining
surface of the horizontal construction joint can be rough floated to thoroughly compact the surface prior to preparing the
surfaces for structural bond.
Stub columns, stub walls, kickers and stays on footings shall be cast integrally with the footings and not afterwards, even where
another class of concrete is being used. This concrete shall be well-compacted and no roughening of the cast surface by rakes
or similar devices that disturb the surface while in the fresh phase shall be permitted.
(ii) Preparing the surfaces
When the concrete has set and while it is still green, the surface film and all loose material shall be removed, without disturbing
the aggregate, by means of a water jet assisted by light brushing to expose the aggregate and leave a sound, irregular surface.
Where this is not possible, the surface film shall be removed after the concrete has hardened, by mechanical means
appropriate to the degree of hardness of the concrete so as to expose the aggregate and leave a sound, irregular surface.
Controlled sand blasting or careful scabbling using light chipping hammers are favourable mechanical techniques. The
Contractor shall where sand blasting and or scabbling techniques are used, prepare a trial section for approval to make sure
the concrete joint is correctly formed. The Contractor shall ensure that the green concrete is not damaged or disturbed during
the preparation of the joint and that any water proofing systems, for example waterstops, are not damaged. The resultant
prepared concrete surfaces shall be entirely free of cracks, spalling, damage, laitance, loose debris, concrete slush and any
other form of contamination.
Acid etching techniques shall not be permitted as this may damage the bond line and compromise water tightness of the
structure. Surface retarding agents may be used only with the approval of the Engineer.
The roughened concrete surface shall be washed with clean water to remove all laitance, dirt and loose particles.
All exposed reinforcement shall be free from loose debris, concrete slush or any form of contamination that may affect its future
bond to concrete.
(iii) Placing fresh concrete at construction joints
Where fresh concrete is placed the same day as that on which the construction joint was formed, the fresh concrete shall be
cast directly against the face of the construction joint.
When concreting recommences a day or more after the construction joint has been formed, the following procedure shall be
followed:
1. The construction joint shall be kept constantly wet for a period of at least 4 hours before concreting restarts, but, the surface of
the concrete shall be in a saturated, surface- dry condition when concreting has to recommence;
2. Any dirt, excess water and loose particles shall be removed prior to reconcreting being started;
3. For horizontal construction joints a 150 to 250 mm thick concrete layer of the same grade of concrete made richer by reducing
the coarse aggregate content by 25 % shall be placed on the joint plane immediately before normal concreting;
4. For vertical construction joints the fresh concrete shall be placed against a surface prepared in accordance with
Clause A13.4.7.11g)(ii), and which is in a saturated, surface-dry; and
5. Where pumped concrete is utilised, the priming slush shall not be permitted to enter into any formwork or structural element to
be cast.
Epoxy resins shall not be used to bond fresh concrete to hardened concrete. For specialist construction methods, for example
precast segmental construction, the particular epoxy adhesive requirements shall be specified on the drawings.
(iv) Waterstops
Where required for water-tight structures or structural elements, waterstops for construction joints shall be as detailed on the
drawings.
Waterstops shall be of plasticised virgin, non-biodegradable polyvinyl chloride (PVC) material and sealing systems shall be of
modified, flexible Polyolefin material, of the type and details as specified on the drawings:
1. Flexible PVC waterstops shall comply with the requirements of CKS 389;
2. Modified, flexible Polyolefin sealing system shall have a minimum tape thickness of 2,0 mm and shall have resistance to diesel
and petrol fuels and oils; or
3. Special Engineered waterstops shall be specified on the drawings.
Each piece of premoulded waterstop or sealing system shall be of maximum practical length in order to keep the number of
end joints to a minimum. All joints in waterstops and sealing systems shall develop effective watertightness fully equal to that of
the continuous waterstop material, shall permanently develop at least 50 % of the mechanical strength of the parent section,
and shall permanently retain their flexibility. Precautions shall be taken so that the waterstops and sealing systems shall be
neither displaced nor damaged by construction operations or other means. All surfaces of the waterstops shall be kept free
from oil, grease, dried mortar, or any other foreign matter while the waterstop is being embedded in concrete. The Contractor
shall ensure that all portions of the waterstop designed for embedment shall be tightly enclosed by dense concrete, particularly
on the underside of horizontal waterstops.
h) Curing and surface protection
The protection of concrete before and during concrete placement, and hardened concrete susceptible to adverse environmental conditions is
described in Clause A13.4.7.10. All classes of hardened concrete shall be cured so as to prevent loss of water and to achieve specified levels
of curing efficiency. Curing shall commence immediately after the bleed water has left the surface and finishing operations are completed.

Where the surface of the concrete begins to dry before the selected curing method can be applied, the surface of the concrete shall be kept
moist by a fine mist spray applied so as not to damage the surface.
When deemed necessary by the Engineer during periods of hot weather, water shall be continuously applied to concrete surfaces being cured
by retaining formwork or by curing compound, until the Engineer determines that a cooling effect is no longer required or the end of the
prescribed curing period has been reached.
Formwork shall be retained in position for the appropriate times given in Clause A13.2.7.3, and as soon as may be practicable, all exposed
concrete surfaces shall be protected from loss of moisture by one or more of the following methods:
(i) Retaining formwork in place for the full curing period;
(ii) Ponding the exposed surfaces with water, except where atmospheric temperatures are low, i.e. less than 5°C;
(iii) Covering it with clean, non-marking sand or absorbent mats made from a moisture-retaining material, and keeping the covering
constantly wet;
(iv) Constantly spraying the entire area of the exposed surfaces with water;
(v) Covering with a waterproof or plastic sheeting firmly anchored and sealed at the edges and joints immediately after wetting the
surface;
(vi) Using an approved curing compound applied in accordance with the manufacturer's instructions, except that, where the surface has to
be subsequently waterproofed, coated or covered with concrete, mortar or sprayed concrete, this method may not be used; or
(vii) Steam curing the concrete (precast units), using saturated steam with maximum temperature of 60°C and covering all exposed areas
to prevent early drying.
The method of curing adopted shall be subject to the Engineer's approval and shall not cause staining, contamination, or marring of the
surface of the concrete. Due care shall be exercised to ensure adherence to the recommended limits for thermal gradients in concrete.
The curing period, represented as either a prescribed minimum strength or curing efficiency, shall be stated on the drawings. Curing efficiency
shall be measured in accordance with the water sorptivity test (refer Clause A13.4.7.9e)). The minimum curing efficiency required shall be the
water sorptivity value determined from trial panels during the mix approval process as adjusted by the permissible deviation. When no such
minimum strength or curing efficiency data is prescribed, the minimum curing period shall be as shown in Table A13.4.7-18.
Table A13.4.7-18: Minimum duration of curing
Minimum daily Minimum curing period1, in days
surface concrete
temperature3, t, in °C Rate of concrete compressive strength development2,
r = (Fcu at 3 days / Fcu at 28 days)
r ≥ 0,55 𝑟 ≥ 0,50 r ≥ 0,45 r ≥ 0,25
t ≥ 25 5 7 10 15
25 > 𝑡 ≥ 15 6 8 11 16
15 > 𝑡 ≥ 5 7 10 15 21
Note: 1) Based on 70% of 28 day compressive cube or cylinder strength.
2) The rate of concrete compressive strength development is the ratio of the mean compressive strength after 3 days to the mean
compressive strength after 28 days determined from initial tests or based on known performance of concrete from site records.
3) Where the ambient relative humidity is below 85 % this value may be increased as directed by the Engineer.
Typically extend curing period by 0,5 days (12 hours) for every 5 %, or part thereof, reduction in ambient relative humidity. When the ambient
surface temperature of concrete falls below 5°C, the minimum curing periods shown in Table A13.4.7-18 shall be extended by the period during
which the temperature of the concrete was below 5°C.
The concrete shall be protected by means of a fog spray to keep it wet constantly for the periods stated above or until a curing compound is
applied. Wetting the concrete by spraying shall be by means of a fixed spraybar along the full length of the formwork. The spraybar shall be
connected to a suitable high-pressure water supply. Wetting shall be discontinued when the ambient air temperature drops below 5°C, and care
shall be taken by the Contractor to ensure that the water will not erode the surface of the fresh concrete.
When sliding formwork is used, the concrete shall be protected against the weather and rapid drying out by means of a 4,0 m wide skirt
attached to the tail of the formwork and if vertical, below the lowest working walkway, both internal and external. The skirt shall consist of two
layers of hessian in summer months but of one layer of canvas or other suitable material in winter. The skirt shall be weighted at the end to
prevent it flapping around in windy conditions.
i) Pipes, ferrules and conduits
No pipes and conduits other than those shown on the drawings shall be embedded in the concrete without the Engineer's approval. Pipes and
conduits shall be embedded in the structural element simultaneously with the casting of the element. The clear space between such pipes or
between such pipes and any reinforcing steel shall be at least 30 mm or the maximum size of the aggregate plus 10 mm, whichever is the
greater. The thickness of the concrete cover over pipes and fittings shall be specified on the drawings but shall be at least 40 mm.
The ends of ferrules used for bracing formwork shall be neatly finished off to the details shown on the drawings. Where no details are given
on the drawings, ferrules shall be cut back to a depth of at least the specified cover, and the holes shall be filled in with mortar and finished off
flush with the concrete surface.
j) Applied loading
(i) General
No load shall be applied to any part of a structure until the specified curing period has expired, the concrete has attained
sufficient strength and, when applicable, sufficient prestressing has been completed, so that damage will not occur. The
decision to permit applied loading to the structure shall rest with the Engineer. The Engineer's decision will be based on the
type of load to be applied, the age of the concrete, the magnitude of stress induced and the propping of the structure.

(ii) Earth loads
Wherever possible the sequence of placing backfill around structures shall be such that overturning or sliding forces are
minimised. When the placement of backfill will cause flexural stresses in the concrete, the placement shall not begin until the
concrete has reached not less than 80 % of the characteristic strength or the curing period has expired, whichever is greater.
(iii) Construction loads
Light materials and equipment may be carried by hand onto deck elements only after the concrete has been in place at least
24 hours, providing curing is not interfered with and the concrete surface is not damaged. Loads in excess of the above, and
those requiring mechanised handling and transport equipment, shall not be carried onto decks until the concrete has reached its
specified characteristic 28 day strength. In addition these loads shall only be permitted once the prestressing has been
satisfactorily completed and approved by the design Engineer and, where required, the deck propping system removed. At no
stage shall bulk materials be stored on decks.
No loads from precast concrete or structural steel elements shall be placed on substructure elements until the concrete reaches
the specified characteristic 28 day compressive strength.
Any layerworks constructed directly over structures shall be compacted only with static rollers. The Contractor shall ensure that
vibratory settings on compacting equipment are not used within the specified minimum limit of the restricted fill and backfill, or
where this is not indicated minimum 3,0 m from the structure.
(iv) Traffic loads
Traffic will not be permitted on concrete decks until all parts of the structure have attained the specified nominal 28 day concrete
strength, at least 14 days after the last placement of deck concrete, completion and approval is issued by the Engineer of the
post-tensioning, curing period and the minimum period for the removal of falsework and formwork.
k) Precast concrete
(i) Manufacturing
This Clause applies to all reinforced and prestressed concrete members other than precast concrete piles and pipes in so far as
they are dealt with separately elsewhere in these specifications.
All precast members shall be manufactured in accordance with the requirements specified for cast in situ members in so far as
these requirements are relevant, in addition to which the following shall apply:
1. The Contractor shall take all necessary safety and precautionary measures during the handling and erection of precast
members and for ensuring the stability of members as positioned and prior to their being cast in or erected;
2. Where precast concrete members have been manufactured off site not under the direct control of the Engineer, the
manufacturer shall keep and make available to the Engineer complete records of all the concrete mixes, strength-, durability-
and cover-tests pertaining to the members cast. The Contractor shall notify the Engineer in advance of the dates on which
members are to be cast to make arrangements for inspecting and testing the precast members;
3. For the purposes of identification, all members shall be marked with paint in neat lettering with the member number shown on
the drawings or as agreed on and an identification number relating to the manufacturing records. Letters and markings shall be
so positioned as not to be visible when the structural member is placed in its final position in the completed structure; and
4. All precast members which have been chipped, cracked, warped or otherwise damaged to the extent that such damage will, in
the opinion of the Engineer, prejudice the appearance, durability, function or structural integrity of the members shall be
rejected or, where so allowed, repaired to the satisfaction of the Engineer.
Where specified on the drawings and where instructed by the Engineer, the surfaces intended for structural bond shall be
prepared and treated in accordance with Clause A13.4.7.12g)(ii) to ensure adequate composite action.
All precast members shall be cured as specified in Clause A13.4.7.12h).
(ii) Safety considerations
Construction activities that utilise precast concrete elements are generally known to be potentially hazardous operations and
each operation will require particular precautionary measures taken by the Contractor to ensure compliance with the
Occupational Health and Safety Act and applicable Construction Regulations, in addition to the limited safety considerations as
addressed below.
1. Storage and stacking
Precast elements shall be stored on suitably graded, engineered platforms with a typical bearing capacity of 500 kPa or
as shown on the drawings. The graded platform shall ensure that the precast items are stable and structurally restrained
against lateral- or torsional- instability during storage. The stacking of precast elements shall only be subject to the
approval of a method statement by the Engineer. No torsional or flexural stresses shall be induced during storage and
stacking that may crack or reduce the structural- and durability-performance of the precast element.
2. Temporary supports
During storage and transportation operations, temporary supports shall be provided for precast elements. Temporary
support shall consist of rubber mats or engineered bearings that provided adequate rotation capacity for the precast
element. The position of temporary supports shall be minimum the design distance as indicated on the drawings from the
edge of the member but a never a greater distance from the outside edge that results in a 98% of the design span length.
The full width of the precast element shall be provided with temporary support.
3. Transportation
The transportation method shall take account of the structural capacity of the precast element. No torsional or flexural
stresses shall be induced during transportation that may crack or reduce the structural- and durability-performance of the
precast element.

4. Placing and erection
Whenever precast elements are hoisted into place, the precast unit shall be stabilised, secured, inspected by the
Contractor’s competent person, approved and signed off as stable prior to the removal of lifting slings and equipment.
Mobile cranes shall not be permitted to take up positions on existing bridge decks when lifting and placing precast beams
or other precast elements.
l) Partial demolition and removal of existing structural concrete
(i) General
All plant, equipment, tools and devices used for the demolition of concrete members shall be based on proven and accepted
technology within the industry. The plant, equipment, tools and accessories shall be inspected and maintained on a regular
basis to ensure that they remain in good working order, function efficiently, and that safety is not compromised. All cutting and
breaking tools shall be kept sharp to reduce the force required to break out concrete to a minimum.
The plant, equipment, tools and devices used for the demolition or removal process shall be of the accepted type and capacity
for the relevant application. The suitability of the chosen method shall be demonstrated on a representative test section
identified by the Engineer prior to the execution of any programmed work.
(ii) Demolition and removal of discrete concrete elements
The demolition of discrete structural elements shall employ techniques that do not damage adjacent structures or structural
components, nor contaminate the surrounding environment.
The Contractor shall ensure that any nuisance associated with his work activity is minimised by implementing appropriate
precautions and measures to the approval of the Engineer. Common nuisances associated with demolition and concrete
removal include fumes, noise, dust, flying fragments, heat and vibration.
Concrete members that are to be demolished completely and removed, shall be broken up into suitably sized fragments to allow
easy removal from site to an approved construction waste facility.
Recommended demolition techniques include the use of percussion breakers, chisels or other approved mechanical equipment,
the use of thermal or hydraulic cutting techniques or by non-explosive chemical means, to ensure minimal damage, for example
micro-cracking, to the existing concrete. Water jet removal of concrete is preferred wherever possible. Demolition by explosive
means shall generally not be permitted.
(iii) Removal of concrete from structural elements
1. Cutting back concrete to a new finished surface
The concrete and reinforcement shall be cut back adequately to provide the prescribed concrete cover to the new finished
surface as specified on the drawings or as directed by the Engineer. The technique used shall be suited to its intended
purpose and shall not cause damage to the remaining concrete member.
Only techniques that do not damage the inherent structure, bond or strength of the remaining sound concrete shall be used.
The thermal cutting technique shall not be used closer than 100 mm from the final surface as indicated on the drawings.
The remaining concrete shall be removed using approved mechanical equipment or hydraulic techniques.
The fixed exposed contact surface shall be bounded by straight line edges cut at least 20 mm depth using a diamond
cutting saw, angle grinder or other approved concrete cutting equipment.
2. Cutting back concrete to expose reinforcement
Where a concrete member has to be joined or extended or replaced by new concrete, the concrete shall be carefully cut or
broken from the reinforcement bars to expose the bars to the dimensions and outline as shown on the drawings or as
directed by the Engineer. Precautionary care shall be taken not to damage or reduce the strength of the exposed bars or
concrete member thereby making them unfit for use. Where reinforcing or concrete is damaged, these shall be made good
at the Contractor’s expense. The remaining concrete contact surface shall be cut to a plane and even surface with exposed
faces perpendicular to the horizontal face or side faces as applicable.
The bounding lines of the cut concrete shall be straight and neat cut to at least 20 mm deep using a diamond cutting saw,
angle grinder or other approved concrete cutting equipment.
A13.4.8 WORKMANSHIP
The tolerance shall be the maximum permissible deviations from the specified dimensions, properties, levels, alignment, positions, etc. shown
on the drawings of the structures or structural members or described in Sections A13.1 to A13.7 after completion of concrete construction. In
addition, the following tolerances and maximum permissible deviations are given below:
a) Concrete quality
(i) Compressive strength
1. Individual valid compressive strength test result:
Minus tolerance ..................................................... 3 MPa less than specified characteristic compressive strength at 28 days.
Plus tolerance ............................................................................................................................................................ unlimited
2. Arithmetic mean of any group of 3 to 29 successive valid compressive strength test results:
Minus tolerance ........................................ Tolerance value as stated in Table A13.4.8-1 greater than specified characteristic
compressive strength at 28 days.
Plus tolerance ............................................................................................................................................................ unlimited
Table A13.4.8-1: Allowable minimum tolerance for mean compressive strength tests
Minimum number of valid Tolerance (minimum)
compressive strength tests
3 +2,0 MPa
4 +3,0 MPa
5 +4,5 MPa
6 +5,0 MPa
10 +6,0 MPa
20 +7,0 MPa
(ii) Oxygen permeability

Minus tolerance (Bave) for the arithmetic mean of 4 samples:
0,25 (log scale) less than specified nominal oxygen permeability at 28 days.
Plus tolerance unlimited
Assessment shall be in accordance with Clause A20.1.7.5 (Plan A) of Chapter 20.
The correlation coefficient (r2) of the linear regression line for each sample shall be minimum 0,990.
(iii) Chloride conductivity
Plus tolerance (Bave) for the arithmetic mean of 4 samples
0,20 mS/cm more than specified nominal chloride conductivity at 28 days.
Minus tolerance unlimited
The porosity of samples determined in the chloride conductivity test shall be minimum 6 % for normal density concrete, or 3 % where chloride
conductivity less than 0,40 mS/cm is recorded.
(iv) Water sorptivity and curing efficiency
Plus tolerance (Bave) for the arithmetic mean of 4 samples
1,5 mm/(hour0,5) more than the approved nominal water sorptivity at 28 days.
Minus tolerance unlimited
The porosity of samples determined in the water sorptivity test in order to assess curing efficiency test shall be minimum 6 % for normal
density concrete.
(v) Cover over reinforcing
(1) For visual inspection prior to casting of concrete, the tolerances shall be as given below.
(1.1) Minimum cover for formed surfaces and unformed finished surfaces:
➢ All elements ................................................................................................................................................... -0 mm
(1.2) Maximum cover for formed surfaces and unformed finished surfaces to:
➢ Elements less than 500 mm thick ................................................................................................................+10 mm
➢ Elements greater than or equal to 500 mm thick ..........................................................................................+15 mm
➢ Elements cast against ground......................................................................................................................+25 mm
(2) For post-casting verification of cover, the tolerances shall be as given below.
(2.1) The mean cover determined per cover survey shall exceed the specified cover minus Cmax, as specified or as shown in Table 13.4.8-
2.
(2.2) The lot shall comply with the requirements specified for concrete cover if the mean cover for the lot is not less than the specified
cover minus the Cave tolerance specified in each case or as shown in Table A13.4.8-2.
Table A13.4.8-2: Values for assessment of cover
Specified cover (mm) Cmax (mm) Cave (mm)
75 15 5
60 12 5
50 10 5
40 8 5
35 7 5
30 6 5

A13.4.8.2 Criteria for compliance with the requirements
Routine inspection and acceptance control will be done by the Engineer as specified in Clause A20.1.7 of Chapter 20 and as specified in the
Contract Documentation. For the purposes of determining compressive strength, the characteristic cylinder strength shall be determined using
100 mm diameter, 200 mm high cylinders prepared in accordance with SANS 3001-CO2-2 and tested in accordance with SANS 3001-CO2-3 at
a sample age of 28 days or 150 mm cube samples prepared in accordance with SANS 3001-CO2-2 and tested in accordance with SANS 3001-
CO2-3. The tensile splitting strength of hardened concrete shall be determined in accordance with SANS 3001-CO2-6. The flexural strength shall
be determined from beam specimens prepared and tested at 28 days in accordance with SANS 3001-CO2-5.
The criteria for compliance with the requirements specified for 28-day characteristic compressive strength shall be as specified in Clause
A20.1.7.5 of Chapter 20 for full acceptance and as specified in Clause A20.1.7.6 of Chapter 20 for conditional acceptance. For durability class
concrete, compliance with the requirements specified for 28-day concrete durability index testing shall be as specified in Clause A20.1.7.5 of
Chapter 20. For all reinforced, prestresssed and precast concrete, compliance with the requirements specified for post-casting cover depth
verification shall be as specified in Clause A20.1.7.5 of Chapter 20. The resubmission of concrete lots on the basis of cores for full or
conditional acceptance shall not be allowed, unless it forms part of the procedures as contemplated in Clause A13.4.8.3. If the Engineer is
satisfied that the requirements of the Contractor's process control have been met, the Engineer may decide at his discretion to use the
Contractor's test results in the evaluation of the concrete.
A13.4.8.3 Procedure in the event of non-compliance with the requirements

Any lot represented by test cylinders, cubes or flexural beams failing to comply with the criteria as specified in Chapter 20 for the characteristic
strength shall be rejected. Any lot represented by concrete durability index testing and or cover depth verification failing to comply with the
criteria specified above for minimum values shall be rejected.
The Engineer may at his discretion allow the following tests to be conducted in order to decide whether the concrete may be left in position at
further reduced payment:
(i) The Engineer may allow the elements or units concerned to be cured for an additional period not exceeding 56 days. Thereafter the
Contractor shall drill cores for compressive strength in accordance with SANS 3001-CO2-3, and the Engineer will evaluate these cores
in accordance with SANS 10100-2. For durability concrete, the Contractor may drill cores for concrete durability index testing in
accordance with SANS 3001-CO3-1 and tested for the relevant concrete durability index; or
(ii) Where the Engineer so directs, full-scale load tests shall be conducted in accordance with SANS 10100-2 to determine whether any
particular structure or member can be left in position at further reduced payment as decided by the Engineer. The cost of such tests
shall be for the Contractor's account regardless of the outcome of the tests. In all cases where concrete has been supplied which fails
to comply with the strength or durability requirements, the Contractor shall immediately take the required remedial action by changing
the mix proportions to obtain the required strength and durability properties.
A13.4.8.4 Tests ordered by the Engineer

Where the routine testing of concrete compressive strength samples, tensile splitting samples, flexural strength beams, energy absorption slabs
and concrete durability test panels is not conducted on the site by the Engineer, he may order the Contractor to have the compressive strength
samples, tensile splitting samples, flexural beams, energy absorption slabs and durability test panels, which have been made by the Engineer,
tested at an approved testing laboratory, in which case payment will be made for such tests in accordance with the provisions of
Clause A20.1.3.6 of Chapter 20.

B13.4 CONCRETE
CONTENTS
B13.4.1 SCOPE
B13.4.2 DEFINITIONS
B13.4.3 GENERAL
B13.4.5 MATERIALS
B13.4.8 WORKMANSHIP
B13.4.1 SCOPE
This Section covers the labour enhanced work in minor bridges, culverts and miscellaneous structures.
This Section covers the supply and storage or stockpile of all materials, manufacture, transport, placing, finishing, curing, protection and testing
concrete in bridges, culverts and miscellaneous structures. The completed concrete elements shall conform to the lines, grades, and
dimensions shown on the drawings and as specified in Section A13.2. The work includes elements of structures constructed by cast-in-place
and precast methods using either plain (unreinforced), reinforced, or prestressed concrete or any combination thereof. This work is
appropriately suited for labour enhanced construction activities.
B13.4.2 DEFINITIONS
B13.4.3 GENERAL

B13.4.5 MATERIALS

B13.4.7 EXECUTION OF WORKS

The provisions of Part A shall apply with the following amendments:
Item C13.4.7.6, reference to Durable (Class D) concrete is not suitable for labour enhanced work
B13.4.7.1 Placing and compaction

Clause A13.4.7.11 provisions shall apply with the following amendment:
Clauses A13.4.7.11c) and e) are not be to be undertaken using labour enhanced construction methods.
B13.4.8 WORKMANSHIP

C13.4 CONCRETE
(i) Preamble
None.
pay items.
5. No separate payment will be made for the hauling of demolished concrete where the material is moved over a distance of less than, and up to
1,0 km and for labour enhanced construction, less than and up to 50 m.
C20.1.2 of Chapter 20 – All
Tests ordered by the Engineer A13.4.8.4
applicable items
C13.4.1 Cast in situ concrete (Class of concrete and use or position in structure stated):
C13.4.1.1 Strength concrete (class C):

Indicate part of structure, class code and 28 day characteristic cylinder
(a) strength/characteristic compressive cube strength and nominal aggregate size e.g. Blinding cubic metre (m3)
C12/15-20
(b) Etc. For other parts of structure cubic metre (m3)
C13.4.1.2 Durable concrete (class D):

(a) strength/characteristic compressive cube strength, environmental exposure and service life cubic metre (m3)
and nominal aggregate size e.g. Deck slab D35/45-XS1(100)-20
(b) Etc. For other parts of structure cubic metre (m3)

C13.4.1.3 Prescribed-composition concrete (class P):
(a) strength/characteristic compressive cube strength and nominal aggregate size e.g. Piers cubic metre (m3)
P32/40-20
(b) Etc. for other parts of structure cubic metre (m3)

C13.4.2 Labour enhanced cast in situ concrete (class of concrete and use or position in
structure stated)
C13.4.2.1 Commercially- Sourced concrete cubic metre (m³)
C13.4.2.2 Contractor-mixed concrete on site cubic metre (m³)

The unit of measurement for cast in situ concrete shall be the cubic metre of concrete in place. Quantities shall be calculated from the
dimensions shown on the drawings or as authorised by the Engineer. No deduction in volume measured for payment shall be made for the
volume of any reinforcing steel, inserts and pipes or conduits up to 150 mm in diameter embedded in the concrete, except for the volume of
void formers, which shall be deducted.
The tendered rate shall include full compensation for procuring and furnishing all the materials, storing the materials, providing all plant, mixing,
transporting, placing and compacting the concrete, forming the inserts, construction joints (except mandatory construction joints and contraction
joints as measured), preparing the surfaces for structural bonding, repairing defective surfaces, and finishing the concrete surfaces as specified.
Payment shall distinguish between the different classes and particular requirements of concrete.
The tendered rate for labour enhanced concrete shall include full compensation for the mix design, the supply of all materials, the production of
the concrete, its transportation to the work site within the haul distance and all activities needed for placing, levelling, compacting, finishing,
curing and protecting the concrete and the repair of defective surfaces
Note: ready-mix concrete shall be delivered to the work face by mixer-truck. Contractor-mixed concrete shall be transported to the work face by
wheelbarrow up to the haul distance of 50 m. When the haulage exceeds 50 m, the concrete shall be transported by dumper for the full
distance, paid as haul.

C13.4.3 Extra over item C13.4.1 for the protection of concrete from adverse environmental
conditions, if required:
C13.4.3.1 Strength concrete (class C):
Indicate part of structure, class code and 28 day characteristic cylinder strength/characteristic
(a) cubic metre (m3)
compressive cube strength and nominal aggregate size e.g. Blinding C12/15-20
(b) Etc for other parts of structure cubic metre (m3)
C13.4.3.2 Durable concrete (class D):

(a) compressive cube strength, environmental exposure and service life and nominal aggregate cubic metre (m3)
size e.g. Deck slab D35/45-XS1(100)-20
C13.4.3.3 Prescribed-composition concrete (class P):

(a) cubic metre (m3)
compressive cube strength and nominal aggregate size e.g. Piers P32/40-20
C13.4.4 Extra over item C13.4.2 for the protection of labour enhanced concrete from adverse
environmental conditions
C13.4.4.1 (Class of concrete and use or position in structure stated): cubic metre (m³)
The unit of measurement shall be the cubic metre of concrete placed in situ where any combination of means described in Clause A13.4.7.11
has been satisfactorily implemented in order to control the temperature of concrete within the specified limits and to adequately mitigate against
adverse environmental conditions.
The tendered rate shall include full compensation for the design, supply, procurement and implementation of the required means of protection
and environmental mitigation and applying it prior to casting and to the fresh concrete surface using approved method until the commencement
of the curing period.
Partial payment shall be applied in the event that the Engineer allows conditional acceptance.

Curing and surface protection of cast in situ concrete, as and where specifically
C13.4.5
required:
C13.4.5.1 Indicate structural element and surface to be cured (Tenderer to specify method of curing): square metre (m2)
C13.4.5.2 Etc for other parts of structure (Tenderer to specify method of curing) square metre (m2))
C13.4.6 Curing and surface protection of labour enhanced cast in situ concrete
C13.4.6.1 Structural element and surface to be stated (Tenderer to specify method of curing) square metre (m2)
The unit of measurement shall be the square metre of completed concrete element cured using an approved method as described in
Clause A13.4.7.12 of these specifications, if and where specifically required on the drawings or as ordered by the Engineer.
The tendered rate shall include full compensation for providing the curing means and applying it to the fresh concrete surface using approved
method(s) and, where applicable, in accordance with the product manufacturer’s specified nominal rates of application satisfying ASTM C309
as amended in Clause A13.4.5.8.
Should no curing method be specified at the time of tender then it will be assumed that wet fine mist spraying curing is to be done. Where
specified, curing shall be assessed by the sorptivity test. Partial payment shall be applied in the event that the Engineer allows conditional
acceptance.
C13.4.7 No-fines concrete (class NF):
C13.4.7.1 Cast in situ:
(a) Indicate class of no-fines concrete and portion of structure or use cubic metre (m3)
(b) Etc for other classes of no-fines concrete and other portions of structures or uses cubic metre (m3)
C13.4.7.2 Precast:
(a) Indicate class of no-fines concrete and describe unit with reference to drawing: number (No)
(b) Etc for other classes of no-fines concrete and units of other types and sizes number (No)
The unit of measurement shall be the number of complete units of each size and type in position in the works.
The tendered rate for each precast unit shall include full compensation for providing all materials, labour, plant and formwork required for the
manufacturing of the unit, complete as shown on the drawings, and for curing, transporting, lifting and placing the unit in position.

C13.4.8 Labour enhanced no fines concrete (Class NF)
C13.4.8.1 Cast in situ (class and portion of structure or use stated) cubic metre (m3)
C13.4.8.2 Precast cubic metre (m3)
The unit of measurement shall be the cubic metre of no-fines concrete in place. Quantities shall be calculated from the dimensions shown on
the drawings or authorised by the Engineer.
The tendered rates shall include full compensation for procuring, furnishing and storing the materials, providing all plant, mixing, transporting,
placing and working the concrete and for curing and protection of the surfaces described in Clause A13.4.7.11f) of the specification.

C13.4.9 Manufacturing precast concrete members (description of member with reference to number (No)
drawing)
C13.4.10 Labour enhanced manufacture of precast concrete members (Description of number (No)
member with reference to drawing)
The unit of measurement shall be the number of complete members or elements of each type and size in position in the works.
The tendered rate for each precast member shall include full compensation for all concrete work, protection from adverse environmental
conditions, all formwork, curing and surface protection, safe guarding, and for all reinforcing steel and all the prestressing as required for
manufacturing the member complete, excluding only prestressing in connection with in situ concrete cast subsequent to the placing of the
precast members, for which prestressing separate payment is provided elsewhere in the schedule of quantities. Where required, the surfaces
shall be prepared for structural bonding with subsequent concrete to the satisfaction of the Engineer.
C13.4.11 Transporting and erecting precast concrete members (description of member and number (No)
approximate mass to be given)
C13.4.12 Labour enhanced transporting and erecting precast concrete members (Description of number (No)
member and approximate mass to be given)
The unit of measurement shall be the number of precast concrete members of each type and size placed into position
The tendered rate for each precast member shall include full compensation for all work, costs, access and equipment required for transporting,
stacking, lifting, erecting and installing the precast concrete member in its final position, complete as specified.

Complete demolition and disposal of existing structural concrete elements or parts
C13.4.13
existing structures:
C13.4.13.1 (Member Indicated) cubic metre (m3)
C13.4.13.2 etc. for other members cubic metre (m3)

The unit of measurement shall be the cubic metre of plain or reinforced concrete demolished for each member scheduled separately in the
schedule of quantities. The quantity shall be measured in its original position and shape.
The tendered rate shall include full compensation for all labour, plant and equipment required to demolish the existing concrete, process the
demolished product to ensure acceptance by the approved construction waste facility, and disposal of the product of the demolition at the
construction waste facility with unlimited haul distance. The tendered rate shall also include full compensation for any necessary measures to
ensure no debris falls into rivers and for any debris that has fallen into rivers to be recovered.
C13.4.14 Controlled demolition of concrete from structural elements:
C13.4.14.1 (Member Indicated) cubic metre (m3)
C13.4.14.2 etc. for other members cubic metre (m3)

The unit of measurement shall be the cubic metre of plain or reinforced concrete removed under controlled conditions for each member or
portion thereof scheduled separately in the schedule of quantities. The quantity shall be measured in its original position and shape and the
modification required as shown on the drawings or approved by the Engineer.
The tendered rate shall include full compensation for all labour, material, screening of the structure for safety and environment protective
measures, plant and equipment as well as for all work and incidentals required to partially demolish the concrete member. The tendered rate
shall also include the processing of the demolished product to ensure acceptance by the approved construction waste facility, loading, lifting,
transport and the disposal of the construction waste at the construction waste facility within a haul distance of 10 km. The tendered rate shall
also include full compensation for any necessary measures to ensure no debris falls into rivers and for any debris that has fallen into rivers to be
recovered.

D13.4 CONCRETE
CONTENTS
D13.4.1 SCOPE
D13.4.2 GENERAL
D13.4.1 SCOPE
D13.4.2 GENERAL
D13.4.2.1 Product Conformance Specifications
The Contractor shall within 28 days of entering into the contract with the Employer submit to the Engineer conformance documentation related to
the specifications. All products used in the manufacture of concrete element shall be in compliance with the specifications continued in Section
A13.4.
Compliance documentation shall be provided for the following;
a) Cement (Clause A13.4.5.1)
b) Supplementary cementitious materials (Clause A13.4.5.1)
c) Aggregates (Clause A13.4.5.2)
d) Water (Clause A13.4.5.3)
e) Admixtures (Clause A13.4.5.4)
f) Integral permeability reducing technology (Clause A13.4.5.5)
g) Fibres (Clause A13.4.5.6)
h) Pigments and integral colouring agents (Clause A13.4.5.7)
i) Curing compounds (Clause A13.4.5.8)
j) Commercially-sourced concrete (Clause A13.4.6.2)
k) Testing necessary to prove the satisfactory execution of the works (Clause A13.4.7)


13.5 PRESTRESSING
CONTENTS
A13.5.1 SCOPE
A13.5.2 DEFINITIONS
A13.5.3 GENERAL
A13.5.5 MATERIALS
A13.5.8 WORKMANSHIP

A13.5 PRESTRESSING
A13.5.1 SCOPE
This Section covers the materials, equipment and work required for prestressing structural concrete members.
A13.5.2 DEFINITIONS
Anchorage - is the device comprising all the components and materials required for retaining the force in a tensioned tendon and to transmit
this force to the concrete of the structure.
Anchorage reinforcement - is the spiral and other reinforcement which forms part of the anchorage and is required for strengthening the
anchorage and/or assisting in transmitting the tendon force to the concrete.
Bursting reinforcement - is the reinforcing steel required in and adjacent to the anchorage zones to resist the tensile or splitting stresses induced
in the concrete by the anchorage(s).
Cable - is the tendon, together with the anchorage, sheathing and all fittings.
Characteristic strength - characteristic strength of prestressing steel is the manufacturer's guaranteed tensile strength below which no more than
5 % of the test results in a statistical population shall fall.
Duct - is the void formed in the structural element to house the tendon(s) and may be formed by coring, or by using sheaths or by way of extractable
cores.
Prestress - is the stress induced in concrete by tensioned tendons.
Prestressed concrete - is structural concrete in which effective internal stresses are induced by means of tensioned tendons.
Pre-tensioned concrete - is prestressed concrete where the tendon has been tensioned before the concrete is cast.
Post-tensioned concrete - is prestressed concrete where the tendon is tensioned after the concrete has hardened.
Pull-in - is the elastic shortening of the tendon caused by relative movement between the anchorage or coupler components on account of seating
and gripping action during or immediately after transfer.
Release - is the specified elastic shortening of the tendon at the anchorage achieved before or during transfer.
Sheath - is the tube or casing enclosing the tendon and which temporarily or permanently allows a relative movement between the tendon and
the surrounding concrete.
Tendon - is the prestressing steel consisting of the bar, wire or strand individually placed, or of bars, wires or strands placed in a duct, all of
which are tensioned to impart prestress to a concrete member.
Tensioning - is the action of inducing and regulating the force in a tendon by means of tensioning and measuring equipment.

Transfer:
- Transfer in the case of post-tensioned concrete is the action of transferring the tensioning force from the tensioning equipment (jack) to the
anchorage.
- Transfer in the case of pre-tensioned concrete is the action of transferring the force in the tensioned tendon(s) to the concrete.
Bond breaker - is the coating or sheath placed on a tendon to prevent it from bonding to the surrounding concrete.
Coupler - is the device comprising all components required to join up two tendons.
Deflector - is the device used to deflect a tendon alignment within a structural element.
Transmission length - is the tendon length required to transmit via bond stresses the full force in the tendon to the concrete.
A13.5.3 GENERAL

the Engineer.

A13.5.4.3 Technical data

The following technical data for pre-tensioned and post-tensioned structural members required for the contract shall be furnished on the
drawings. Where this information is not provided, the Contractor will request the information.
a) Tendon alignment
A diagram showing the alignment of each tendon or group of tendons in both the horizontal and vertical planes, together with the horizontal and
vertical coordinates, and curve equations of the centroid of the tendon(s), as may be relevant.
b) Tendon system
The design is based on the system shown on the drawings, but the Contractor may use any suitable system which will meet all the specified
requirements, subject to approval by the Engineer.
c) Tensioning the tendons
Full particulars regarding the partial tensioning of the tendons, the stage during which the tendons shall be tensioned, and the sequence of
tensioning to be followed.
d) Tensioning force
The maximum tensioning force and the effective force at the live anchorages, after transfer, as well as the corresponding stress level in the
prestressing steel, for each tendon or group of tendons. The forces will be given in MN units, and the stress levels will be expressed as a
percentage of the characteristic strength.
e) Extension
The extension per tendon or group of tendons under the maximum tensioning force, together with the modulus of elasticity (E) on which it has
been based. The release to be attained at each live anchorage as well as the pull-in for which provision has been made.
The Contractor shall show on his drawings the expected extension based on the actual modulus of elasticity of the strand as well as the
expected wedge pull-in and any provision for shimming.

f) Prestressing losses in tendons
The losses allowed for in the design from the causes listed below will be given as follows:
(i) Friction loss
The formula used for determining the tendon/duct friction loss together with the values adopted for the friction coefficient (μ)
caused by curvature, and the wobble factor (k) caused by unintentional variation from the specified alignment.
(ii) Elastic deformation of concrete
The elastic factor, which, when multiplied by the compressive stress in the concrete adjacent to the tendon, will give the loss
caused by the deformation of the concrete.
(iii) Creep of the concrete
The creep factor, which, when multiplied by the compressive stress in the concrete adjacent to the tendon, will typically give the
loss caused by the creep of the concrete.
(iv) Shrinkage of the concrete
The stress loss in MPa caused by the shrinkage of the concrete.
(v) Relaxation of prestressing steel
The stress loss in MPa at a stress level of 70 % of the characteristic strength of the prestressing steel caused by the relaxation
of the prestressing steel.
g) Anchorages
The positions where loop or fan-type dead-end anchorage may be used.
h) Bursting reinforcement
The bursting reinforcement for the prestressing system on which the design is based.
i) Precamber
The precamber at intervals not exceeding 0,25 times the span length.
j) Compressive strength of the concrete during transfer
The compressive strength to be attained by the concrete in the relevant member before transfer may take place.
A13.5.4.4 Prestressing systems

The use of all prestressing systems shall be subject to approval by the Engineer. Tenderers are advised to obtain approval for the prestressing
system they intend using, prior to submitting their tenders.
Within one month of the tender having been awarded, or within a period agreed on with the Engineer, the Contractor shall submit full details
regarding the prestressing system(s), materials and equipment he intends using, as well as regarding the methods he proposes to adopt in the
prestressing and related operations.
The Engineer, at his own discretion, may call for further information in the form of detailed drawings, proof of successful previous use,
performance certificates from an approved independent testing authority, and calculations substantiating the adequacy of the system. The
Contractor shall furnish such information within 2 weeks of being called upon to do so or within a period agreed to with the Engineer. If, after
investigating all the information, the Engineer is not satisfied that the prestressing of the structural member can be carried out satisfactorily with
the prestressing system offered by the Contractor, the Engineer reserves to himself the right to order the Contractor to use any system which is
suited to the work and which is readily available to the Contractor.
Only minor alterations to the concrete dimensions shown on the drawings will be considered in order to accommodate the prestressing system
finally selected. Major alterations occasioned by the prestressing system offered by the Contractor and which is at variance with the tendon
system specified in Clause A13.5.4.3b) shall be treated as alternative designs and shall be dealt with as specified in the General Conditions of
Contract.
A13.5.4.5 Drawings prepared by the Contractor

All drawings prepared by the Contractor and submitted to the Engineer for consideration shall comply with the requirements of A1.2.4 of
Chapter 1.
The Contractor shall submit to the Engineer at least 2 months before he intends commencing with the manufacturing of concrete element to be
prestressed, drawings detailing the layout and alignment for the individual tendons, the cable supports, modifications to the bursting and other
reinforcement, anchorage recesses, tensioning sequence, tensioning loads and extensions, as well as requirements for controlling the
tensioning operations. For the prestressing system finally selected, the technical data which are at variance with the information given on the
drawings shall be shown on the drawings. Each tendon shall be separately numbered for identification.
The drawings shall also show the anchorage reinforcement required for the prestressing anchorages and couplers, as well as any modifications
that may be required to the bursting reinforcement. The cost of supplying and fixing the anchorage reinforcement shall be included in the rate
for anchorages and couplers.
Where required, the Contractor shall submit calculations in respect of the variation of the tendon force along the length of the tendon, the
expected extension and the bursting forces.
After approval by the Engineer of the drawings and calculations submitted by the Contractor, no departure shall be permitted from the forces,
stresses and extensions shown thereon, without authorisation by the Engineer.
The manufacturing of concrete elements to be prestressed shall not commence before the relevant drawings have been accepted by the
Engineer.
The Contractor shall make full allowance in his tendered rates for all costs in connection with the furnishing of information, making calculations,
and preparing and submitting the drawings. However, no allowance need be made for the cost of checking, undertaken by the Engineer, of
drawings and calculations for work which does not qualify as an alternative design.
Alternative designs shall comply with the requirements of the General Conditions of Contract and the relevant provisions of this Section.
A13.5.5 MATERIALS
A13.5.5.1 General
All materials and prestressing systems used in the prestressing of structural concrete members shall be subject to approval by the Engineer.
A13.5.5.2 Prestressing steel

a) General
The type of prestressing steel shall be designated in accordance with the requirements of Clauses A13.5.5.2b) and c).
The Contractor shall keep proper records of all material analyses and test certificates for the batches of prestressing steel used in the works.
Where required by the Engineer, the Contractor shall produce certificates from recognised testing authorities certifying compliance of the
prestressing steel with the specified requirements.
Where prestressing steel is available in weld-free lengths (production lengths) and lengths containing welds (standard lengths), the batches
delivered at the site shall be clearly labelled for identifications purposes.
In no circumstances shall prestressing steel after manufacture be subjected to heat treatment other than as provided for in these specifications.
b) Bars
Cold-worked high-tensile alloy steel bars for prestressed concrete shall comply at least with the requirements of BS 4486.
The type of prestressing steel shall be indicated in accordance with the requirements of Clause 4.2 of BS 4486, e g BS 4486-RR-32-1230 for 32
mm diameter ribbed bar with a nominal tensile strength of 1 230 MPa.
c) Wires and seven-wire steel strand
Steel wire and seven-wire steel strand for prestressed concrete shall comply at least with the requirements of BS 5896.
The type of prestressing steel shall be indicated in accordance with the requirements of Clauses 14 and 20 of BS 5896 for wire and strands
respectively, e.g.:
(i) BS 5896/2 wire 1770-7-PE-relax 1 for a 7,0 mm nominal diameter straightened smooth wire of class 1 relaxation with a nominal tensile
strength of 1 770 MPa; and
(ii) BS 5896/3 superstrand 1860-12,9-relax 2 for a 12,9 mm nominal diameter seven-wire superstrand of class 2 relaxation with a nominal
tensile strength of 1 860 MPa.
d) Straightness
Prestressing bars delivered at the site shall be straight. Only small adjustments for straightness may be made, which shall be done by hand on
the site at a temperature above 5C and under the supervision of the Engineer. Where heating of the bars is required, this shall be by means of
steam or hot water. Bars bent in the threaded portion shall not be used.
Prestressing wire and strand shall be supplied in coils with a sufficiently large diameter to ensure that the wire and strand will pay off straight.
e) Surface condition
Prestressing steel shall be clean, free from faults or defects, and without any harmful films and matter which may impair adhesion to the grout
or concrete. A film of rust is not necessarily harmful and may improve the bond. It may, however, increase the friction between the tendon and
duct.
The depth of imperfections or pits on the surface of prestressing steel shall not exceed 0,1 mm for wire with a diameter up to and including 8,0
mm, or 0,2 mm for bars or wire with a diameter exceeding 8,0 mm.
Tendons may be cleaned by wire brushing or by passing through a pressure box containing carborundum powder. Solvent solutions shall not
be used for cleaning without the approval of the Engineer.
Prestressing steel shall be delivered at the site suitably protected against damage and corrosion. Such protection or the use of a corrosion
inhibitor where allowed by the Engineer, shall not have any deleterious effect on the steel or concrete or impair the bond between the two.
f) Galvanising
Galvanised prestressing steel shall not be used unless specified. In no circumstances shall prestressing steel be subjected to galvanising after
manufacture.
g) Welds
Prestressing steel used in structural prestressed concrete shall be weld-free. Where the steel is supplied in standard lengths, the welds shall
be cut out and delivered to the Engineer.
A13.5.5.3 Anchorages and couplers

Anchorages and couplers to be used in prestressed concrete shall comply with the requirements of BS EN 13391 and shall be of a proved and
approved type, constructed from durable material completely free from imperfections and shall not damage, distort or kink the prestressing steel
in a manner as will result in ultimate tensile strength reduction. They shall resist, without failure and/or excessive deformation or relaxation of
the force in the tendons, the full ultimate tensile strength of the tendons. The characteristic value for anchorages and couplers, determined in
accordance with BS EN 13391, shall not be less than 90 %.
The anchorages shall effectively distribute the force in the tendon to the structural member, and the resulting local stresses and strains in the
member shall be so limited as to prevent damage. Unless otherwise approved by the Engineer, all anchorages and couplers shall be provided
with anchorage reinforcement.
Wedges and the insides of barrels or cones shall be clean to allow the free movement and seating of the wedges inside the taper.
The threads of bars, nuts, anchorages and couplers shall be suitably protected against damage and corrosion. The protection shall be removed
at the last moment and the threads properly lubricated before use.
A13.5.5.4 Sheaths
Sheaths shall be grout-tight and of such material and configuration that bond forces can be transferred from the grout to the surrounding
concrete. The properties of the sheath material shall be such that no corrosion attack of the prestressing steel will be induced. The sheath
shall be sufficiently flexible to accept the required curvature without kinking, and strong enough to retain its cross-section and alignment and to
resist damage on account of handling, transporting, tying and contact with vibrators during concreting. Unless otherwise approved by the
Engineer, the thickness of the metal of steel sheaths shall not be less than 0,4 mm.
Metal sheathing shall be delivered at the site suitably protected against damage and corrosion. At the time of incorporation into the structural
member, the sheathing shall be free from loose mill scale, loose rust, lubricants and harmful matter.
Galvanized sheathing shall not be used unless specified.
Plastic sheaths shall be formed using HDPE corrugated piping in accordance with ‘Corrugated Plastic Ducts for Internal Bonded Post-
tensioning’, Bulletin No. 7, International Federation for Structural Concrete (fib), January 2000.
Unless otherwise specified, the internal diameter of the sheath shall be at least 10 mm greater than the diameter of the tendon. For vertical
tendons and where tendons are to be drawn into cast-in sheaths, the cross-sectional duct area shall be at least three times the cross-sectional
area of the tendon.
A13.5.5.5 Cable supports

Supports of reinforcing steel or structural steel suitably braced to prevent buckling under load shall be used to support the cables. The cable
saddles shall be rigid and secured in position by welding or by equivalent mechanical means to resist both gravitational and buoyancy forces.
Normal web reinforcement shall not be utilised to support cables.
Saddles for external cables shall be of special design and material to ensure low friction and to prevent the tendon or parts thereof from
grooving the surface. The saddle plates shall be curved to the requisite radius to prevent the tendon or part thereof from bearing on the end of
the plate.
A13.5.5.6 Tendon spacers

Tendon spacers used inside the ducts to separate individual bars, wires or strands of the tendon shall be of a proved and approved type and
manufactured from material which will not induce corrosion of the prestressing steel.
A13.5.5.7 Grout
a) Materials
In addition to the requirements of Clause A13.4.5.3, water shall not contain more than 500 mg of Cl ions per litre of water.
Only CEM I or CEM II/A, with a strength class of 42.5 N or greater, which complies with the requirements of SANS 50197 shall be used. The
temperature of the cement shall be less than 40C, and the cement shall be stored in accordance with the requirements of Clause
A13.4.5.10b).
Fine aggregate shall consist of siliceous granules, finely ground limestone or very fine sand. The aggregate used shall pass through a
0,600 mm sieve. The use of fine aggregate shall be subject to the approval of the Engineer and shall be restricted to grout for ducts with a
diameter exceeding 150 mm. The aggregate content in the grout shall not exceed 30 % of the mass of the cement.
The use of admixtures shall be subject to tests having shown that their use improves the properties of the grout, e g by increasing workability,
reducing bleeding, entraining air, or expanding the grout. Admixtures shall be free from any product liable to damage the steel or the grout
itself, such as halides, nitrates, sulphides, sulfates, etc. The quantity of admixture to be used shall be in accordance with the manufacturer's
instructions.
b) Properties of the grout
The mixed grout shall have the following properties:
(i) The Cl ions content shall not exceed 750 mg per litre.
(ii) The viscosity of the grout measured in accordance with Clause A13.5.5.9(d) for horizontal cables shall be 500 to 2 500 cP and for vertical
cables 400 to 1 500 cP. The viscosity of the grout, 20 minutes after mixing, shall not exceed 2 500 cP and 1 500 cP for horizontal and
vertical cables respectively.
(iii) Bleeding at 20C measured in accordance with Clause A13.5.5.9d) shall not exceed 2 % by volume 3 hours after the grout has been
mixed, and the maximum bleeding shall not exceed 4 %. In addition, the separated (bleed) water must be reabsorbed after 24 hours.
(iv) The cube compressive strength of 100 mm cubes made of the grout and cured in a moist atmosphere for the first 24 hours and then in
water at 20C shall exceed 20 MPa at 7 days.
A13.5.5.8 Protecting agents for unbonded tendons

The material used for permanent protection of unbonded tendons shall have the following properties:
a) It shall remain free from cracks and shall not become brittle or fluid within the temperature range of -20C to 70C.
b) It shall be chemically stable for the entire life of the structure.
c) It shall be non-reactive with the surrounding materials, i e concrete, tendons, wrapping or sheathing.
d) It shall be non-corrosive or corrosion-inhibiting.
e) It shall be impervious to moisture.
f) It shall be sufficiently tough to withstand the abrasion caused when a tendon, precoated with the material, is drawn into the sheath.
g) It shall have no appreciable shrinkage or excessive volume increase.
h) It shall have a suitable viscosity at ambient temperature or require only moderate preheating to permit injection.
A13.5.5.9 Testing
a) General
Where so directed by the Engineer, the Contractor shall make arrangements for samples of the materials he intends to use in the works to be
tested by an independent testing authority. The cost of testing prestressing steel, anchorage assemblies and couplings shall be paid for as
specified in Section C20.1 of Chapter 20 on condition that the product complies with the requirements. Control tests on the viscosity and
bleeding of grout will be regarded as part of the Contractor's obligations under Chapter 1 for process control and will not be paid for separately.
Material represented by samples which do not comply with the specified requirements, shall be removed and replaced with suitable material.
b) Anchorages and couplers
Anchorages and couplers shall be tested in accordance with the requirements of Clause A13.5.5.3. The anchorages and couplers shall be
assembled in accordance with their practical application on the site where all the components necessary for anchoring shall be used, but
excluding the ducts.
c) Prestressing steel
Prestressing steel shall be tested in accordance with the requirements of Clause A13.5.5.2. Should any test piece fail to comply with the
requirements specified for the prestressing steel, the material represented by that sample shall not be used without further testing and shall be
replaced with materials conforming to the specifications, if further testing confirms that they do not comply with the specifications.
d) Grout
The fluidity of grout shall be measured with a flow cone, immersion apparatus or viscometer. The instrument shall be accurately calibrated in a
laboratory so that the specified viscosity of the grout can be controlled satisfactorily.
The procedure for conducting the flow-cone test for measuring the fluidity of grout shall be as follows:
Unless otherwise approved, the flow cone shall be as shown in Figure A13.5-1.
Immediately after the grout has been mixed, the pre-wetted flow cone, which is held firmly with its top rim in a level position, shall be filled with
grout to the level indicated by the pre-set pointer, whilst the bottom orifice is held closed with a finger.
As soon as the required volume of grout, (± 1 750 ml), is reached, the finger shall be released to allow the grout to flow out freely through the
bottom orifice. A stop watch shall be used to determine the flow time for emptying the cone, to the nearest second.
The readings obtained during grouting shall be compared with the times determined in the laboratory for grouts of the specified viscosities.
The bleeding of grout shall be measured in a metal or glass container with an internal diameter of approximately 100 mm and a height of
approximately 120 mm. The grout and water levels in the container shall be controlled with a metal bridge into which two adjustable studs A
and B are secured. See Figure A13.5-2 for details of the apparatus.
The procedure for determining the bleeding of grout shall be as follows:
Studs A and B in the metal bridge shall be adjusted and locked so that the distance from the lower tips of the studs to the bottom of the
container will be approximately 100 mm and 107 mm respectively. The volumes VA and VB for the container at the respective levels of the stud
settings shall then be determined to the nearest millilitre.
The container shall be filled with freshly mixed grout to a level where the grout will just touch the tip of stud A which points downwards. The
bridge shall then be removed and the container tightly sealed to prevent evaporation. The container shall then be stored at 20°C and kept free
from vibrations for the entire duration of the test.
Three hours after the grout has been mixed, the container shall be opened and the free (bleed) water poured off. The bridge shall be placed
over the container with the tip of stud B pointing downwards and water poured onto the grout with a measuring apparatus until the water level
touches the tip of stud B. The volume of water added shall be determined to the nearest millilitre and designated as ΔV.
The percentage of bleeding shall be calculated from the formula: [ 1 – ( VB – ΔV ) / VA ] x 100

Figure 13.5-1: Flow Cone Figure 13.5-2: Metal or Glass Container

A13.5.6.1 General
All equipment used shall be in a good working order, and properly maintained and suitable for its indicated use.
A13.5.6.2 Tensioning and measuring equipment

Tensioning and measuring equipment shall be such that the tendon force can be established to an accuracy of ± 2 % during any stage of the
tensioning operation.
Unless otherwise authorised by the Engineer, the tensioning equipment shall be power driven and capable of gradually applying a controlled
total force without inducing dangerous secondary stresses in the tendon, anchorage or concrete.
The force in the tendon during tensioning shall be measured by a direct-reading dynamometer (load cell type) or obtained direct from pressure
gauges fitted in the hydraulic system to determine the pressure in the jacks.
Pressure gauges shall have concentric scale dials which comply with the requirements of BS EN 837-1. The dials shall not be less than 150
mm in diameter and the gauges shall be used within the range of 50 – 90 % of their full capacity at maximum service pressure.
When pressure gauges not using glycerine are used, a snubber or similar device shall be fitted to protect the gauge against any sudden release
of pressure. Provision shall also be made for T-connections for the attachment, when required, of supplementary control gauges.
Only self-sealing connections shall be used in the hydraulic circuit. Where the pressure input pipe is connected to the jack, a pipe rupture valve
shall be installed in the circuit.
Tensioning equipment shall be calibrated before the tensioning operation and thereafter at frequent intervals, as directed by the Engineer, with
a master gauge or proving ring, and the Engineer shall be furnished with a calibration chart. The load-measuring devices shall be calibrated to
an accuracy of ± 2 %.
The extension of tendons shall be measured to an accuracy of ± 2 % or ± 2,0 mm, whichever is the more accurate, and pull-in and release to an
accuracy of ± 2,0 mm.
A13.5.6.3 Grouting equipment

a) Mixer
Mechanically operated mixers only, of a type capable of producing high local turbulences while imparting only a slow motion to the body of the
grout shall be used.
The mixer shall be equipped with a screen with openings not exceeding 1,0 mm and shall be capable of consistently producing grout with a
colloidal consistency.

b) Agitator
Where the capacity of the mixer is insufficient to fill the duct completely with grout, an agitator shall be used.
Mechanical agitators only shall be used, which are capable of maintaining the colloidal condition of the grout fill during the storing and injection
processes. The grout shall be delivered at the structure from the agitator, and the system shall make provision for recirculating the grout from
the pump back to the agitator.
c) Injection equipment
The pump shall be of the positive displacement type (piston, screw or similar type), capable of exerting a constant pressure of at least 10 bars
on completely grouted cables and shall incorporate a safety device for preventing the build-up of pressure above 20 bars. The pump shall be
fitted with a pressure gauge and a valve which can be locked-off without loss of pressure in the cable.
The pump shall be capable of delivering grout at a speed as will produce a speed of the grout in the cable of between 6,0 and 12 m per min.
All connections in the pipes and between the pipe and the cable shall be airtight. Only bayonet, threaded, or similar types of connectors shall
be used.

A13.5.7.1 Precasting
a) Casting yard on the site
Subject to approval by the Engineer, precast work may be done at any location selected by the Contractor.
Before the casting yard is established, the Contractor shall submit plans to the Engineer which demarcate the site and detail the layout of the
works, together with a flow diagram of the construction stages and storage.
b) Manufacture off the site
The Contractor shall notify the Engineer in advance of the dates when tensioning of tendons, casting of members and transfer, will be
undertaken.
Within 7 days of transfer, the Contractor shall submit to the Engineer a certificate giving the tendon force(s) and extension(s) attained as well as
records of the cube crushing strength and age of concrete at transfer.
Test results relating to all aspects of the work shall be sent to the Engineer immediately after becoming available.
Where the Engineer requires tests to be conducted on completed members, no member to which the tests relate shall be dispatched to the site
until the tests have been satisfactorily completed and the members accepted by the Engineer.
c) Manufacture
Before work is commenced, details of the manufacture, curing and phasing of the work shall be submitted to the Engineer for approval. After
approval no changes shall be made to the methods or systems without approval by the Engineer.
The Contractor shall ensure that the specified precamber is incorporated in the formwork. The magnitude of the precamber shown on the
drawings shall be subject to variation depending on the Contractor's construction programme, and the Contractor shall, before manufacture,
ascertain in writing from the Engineer, the increase or decrease in precamber. This procedure shall also apply to the cases where no
precamber has been specified.
Lifting and supporting the precast members shall be made only at the points marked and provided on the members.
Precast members which have not been fully tensioned or fully stage-tensioned or which have ungrouted tensioned tendons shall not be handled
without authorisation by the Engineer.
Where members with ungrouted tensioned tendons are handled, control shall be exercised to guard against possible slip of the tendon at the
anchorage.
Prestressed precast concrete members shall also comply with the requirements of Clause A13.4.7.11k).
A13.5.7.2 Pre-tensioning
During the period between tensioning and transfer, the force in the tendon shall be fully maintained by some positive means. At transfer,
detensioning shall take place slowly to minimise any shock which could adversely affect the transmission length of the tendon.
In the long-line method of pre-tensioning, sufficient locator plates shall be distributed through-out the length of the bed to ensure that the
straight tendons are maintained in their proper position during concreting. Where a number of units are manufactured in line, they shall be free
to slide in the direction of their length so as to permit transfer of the tendon force to the concrete along the entire line.
In the individual-mould system, the moulds shall be sufficiently rigid to provide the reaction to the tendon force without distortion.
Where possible, the mechanism for holding down or holding up deflected tendons shall ensure that the part in contact with the tendon will be
free to move in the line of the tendon so that friction losses are eliminated. If, however, a system is used which develops a frictional force, this
force shall be determined by test and due allowance made therefor.
For single tendons, the deflector in contact with the tendon shall have a radius of not less than 5 times the tendon diameter for wire, or 10 times
the tendon diameter for a strand, and the total angle of deflection shall not exceed 15.
Transfer of the tendon force to the concrete shall be effected in conjunction with the release of hold-down and hold-up forces in accordance with
an approved method.

Transfer shall not be effected until compressive-strength tests on the concrete show that the concrete of the particular member has attained a
compressive strength of at least the compressive strength shown on the drawings. The transmission length is affected by the concrete
strength, and the necessary modification for the concrete strength at transfer shall be made in conjunction with the Engineer.
The tendons shall be cut off flush with the end of the member and the exposed ends covered with a heavy coat of approved bituminous material
or epoxy resin or as instructed by the Engineer. The cutting of the prestressing steel shall be performed with a high-speed abrasive cutting
wheel. Flame cutting will not be permitted.
A13.5.7.3 Post-tensioning
a) Storage, handling and protection
During storage, transit, construction and after installation, the sheaths, prestressing steel, anchorages and couplers shall be protected against
corrosion, damage or permanent deformation. The manner and extent of protection required will depend on the environmental factors and the
length of time before permanent corrosion protection is applied, and shall be to the satisfaction of the Engineer. Under severe corrosive
conditions in coastal, damp and wet areas and under aggressive conditions the materials shall be stored in weatherproof sheds. All materials
shall be stored clear of the ground and while in storage shall not be exposed to the weather.
When prestressing steel has been stored for a prolonged period and there is evidence of its deterioration, the Contractor may be called on to
prove by tests that the quality of the steel has not been significantly impaired and that the prestressing steel still complies with the provisions of
these specifications.
Suitable protection shall be provided to the threaded ends of bars.
After fabrication, the cable ends shall be covered with protective wrapping to prevent the ingress of moisture into the duct.
When the tendon is to be left untensioned for a prolonged period after installation, precautions shall be taken to protect the tendon against
corrosion. Corrosion inhibitors, soluble oils or similar materials used as lubrication or to provide temporary protection shall be such that they
can be completely removed before permanent protection is affected.
b) Fabrication
All cutting of prestressing steel shall be performed with a high-speed abrasive cutting wheel or by a method approved by the Engineer. Flame
cutting will not be permitted.
Care shall be taken to prevent the prestressing steel or anchorages from coming into contact with splashes from flame-cutting or welding
processes in the vicinity.
Where possible, all bars, wires or strands tensioned in one operation shall be taken from the same parcel of prestressing steel. The tendon or
cable shall be labelled to show the tendon or cable number, as well as identify from which parcel the steel has been taken.
Where bars, wires or strands in a tendon are not tensioned simultaneously, tendon spacers shall be used in accordance with the
recommendations for the prestressing system or, in the absence thereof, as directed by the Engineer.
Cables shall be fitted at both ends with pipes with a diameter of at least 10 mm for the injection of grout or protection agents. The ends of the
injection pipes shall be fitted with a clamp, valve or device capable of withstanding a pressure of at least 15 bars without loss of grout or
protection agent.
Vent pipes with a diameter of at least 25 mm shall be provided in the duct at every high point, low point, change of sheath cross-section and at
such intermediate positions as may be shown on the drawings or required by the Engineer. The vent pipes shall extend to at least 500 mm
above the concrete and shall comply with the requirements for injection pipes.
Connections to, and joints in sheaths shall be made grout-tight by using special sheathing couplings and taping. With bonded cables, the
length of taping shall not exceed six sheath diameters. Where oversleeves are used, equal overlaps shall be provided over each length of
sheathing. Joints in adjacent sheaths shall be spaced at least 300 mm apart.
c) Installation
The installation of tendons shall not commence until the requirements of Clause A13.5.4.5 have been complied with.
The cable, sheath or extractable core shall be accurately installed to the specified alignment and securely held in position both vertically and
horizontally at intervals appropriate to its rigidity and so as not to be displaced during concreting, either by the weight of the concrete or by
buoyancy. The spacing of the cable supports shall furthermore ensure that the tendon can be installed to a smooth alignment without kinks and
within the tolerance specified in Clause A13.5.8.1. Cable sheaths shall be supported and held in position by means of separate reinforcing
steel supports with a diameter of not less than 16 mm. The transverse bars must be welded to the vertical bars or must rest on lugs welded to
the vertical bars. The spacing of the vertical supports shall not exceed 1,0 m.
Extractable cores shall not be coated with release agent unless approved by the Engineer.
Unless otherwise shown on the drawings, the alignment of the tendon within a distance of 1,0 m from the live anchorage and/or coupler shall be
straight. The tendon axis shall be set perpendicular to the bearing surface of its anchorage and firmly secured in position so as not to move
during concreting. External anchorages shall be seated on a thin mortar bedding to bear evenly on the concrete bearing surface, and the
tendon axis shall be perpendicular to the bearing surface of the anchorage.
Unless otherwise shown on the drawings, the minimum concrete cover over the outside surface of the sheath or cable support shall comply with
the requirements of Clause A13.3.7.4, except that, for sheaths, the cover shall not be less than 50 mm.
The spacing of cables will depend on the size of the cable and shall be such that the concrete can be properly placed and compacted.
Immediately before concreting, the Contractor shall inspect the sheaths for grout-tightness and shall seal all damaged and suspect sections.
External tendons shall be installed to the same standards and accuracy specified herein for internal tendons. The tendons shall be temporarily
supported at regular intervals along the straight length between saddles. The supports shall consist of rigidly constructed frames secured to the
concrete face.

d) Concrete strength
Full tensioning of all or some of the tendons shall not commence until the compressive-strength of the concrete is 35 MPa or the strength
shown on the drawings, whichever is the greater. Irrespective of concrete strength, full tensioning shall not commence within 7 days after
completion of the last concrete pour affected by the prestressing.
The 7-day period may be reduced for certain forms of construction such as Incremental Launching, Balanced Cantilever or Precast Segmental
Construction. The Contractor shall submit a request to reduce the 7-day period to the Engineer for approval at least 28 days before
construction of that part of the works commences. The request shall include a method statement that demonstrates that the concrete
compressive strength and tensile strength has reached the required strengths prior to prestressing.
The compressive strength of the concrete shall be determined from cubes manufactured and tested in accordance with the relevant SANS
3001-CO1 and CO2 test methods, which have been cured under the same conditions as the structural member which is to be prestressed. The
number of concrete cubes required for this purpose shall be as agreed on with the Engineer.
Where initially all or some of the tendons are to be partially tensioned, tensioning shall not commence before the concrete has attained the
compressive strength indicated on the drawings.
e) Tensioning
(i) Preparation
Within 2 hours of the concrete having been placed, the Contractor shall demonstrate that sheaths are free from obstructions, that
extractable cores can be removed and, where the design permits, that all tendons are free to move in the ducts. All water in the
ducts shall then be expelled with compressed air and the cables sealed until tensioning takes place.
Before tensioning is commenced, the side forms and other restraining elements shall be released or removed to give the
structural member the freedom to deform under the induced force.
(ii) Tensioning sequence
The sequence of tensioning to be followed shall be as shown on the drawings and/or on drawings prepared by the Contractor in
terms of Clause A13.5.4.5. The Contractor shall make allowance in his tendered rates for all incidentals which he may have to
incur as a result of having to tension fully only some of the tendons at any one stage or instant.
Where partial tensioning of tendons is required, the work shall be executed in accordance with the details on the drawings or as
specified. The Contractor shall, in his tendered rates, make provision for all incidentals he may have to incur as a result of having
to tension partially only some of or all the tendons at any one stage or instant.
Where the elastic shortening in the falsework prior to prestressing exceeds the uplift in the deck caused by prestressing, the
falsework shall be lowered to prevent unintended loads and cracking. The procedure for stressing part of the prestressing, then
lowering the falsework, followed by completion of the stressing, shall be submitted to the Engineer for approval in terms of Clause
A13.2.7.3d).
(iii) Assembling the equipment, and safety precautions
The tensioning and measuring equipment shall be assembled for tensioning in exactly the same way as they are combined for
calibration.
The Contractor shall take all the necessary safety precautions to prevent accidents caused by the malfunctioning or failure of any
part of the equipment or material and shall accept full responsibility for injury sustained by persons or damage to property
resulting therefrom.
(iv) Friction
The Engineer may require the Contractor to perform friction tests on designated tendons and to revise the relevant theoretical
extensions to compensate for the discrepancy between the values adopted in the design and the test results. Payment for these
tests shall be made under Section C20.1 of Chapter 20.
Where applicable, allowance shall be made in the tensioning force to compensate for friction loss in the jack and in the
anchorage.
(v) Tensioning
Tensioning shall be carried out under the supervision of a technician skilled in the use of the prestressing system and equipment
and the methods of tensioning to be adopted.
Tensioning shall not be commenced before the Engineer has been advised of each tensioning operation and has given his
approval for the work to be started.
The technician and operators shall be supplied with a schedule listing the sequence of tensioning the various tendons and a
tensioning record sheet showing the theoretical gauge readings, jacking forces, extensions, release and pull-in for each
tensioning operation. The record sheet shall furthermore provide room for entering the corresponding information recorded and
observations made during tensioning. A graph of the tensioning force and/or gauge reading versus theoretical extensions shall,
where required, be appended to the record sheet and the actual extensions measured for each load increment shall be plotted on
the graph. Copies of the completed record sheets and graphs shall be submitted to the Engineer within 24 hours of each
tensioning operation having been completed.
The Contractor shall note that the extensions shall be regarded as an indirect measurement of the tensioning force and shall
serve as a control on the tensioning force applied.
The protruding ends of all bars, wires and strands shall be clearly marked for the accurate measurement of extension, release
and pull-in.
Before tensioning is commenced on external tendons, a small load shall be applied to each tendon, commencing with the
uppermost tendon. The force shall be sufficient to take up all slack and prevent entanglement of the tendons.

The jacking force shall be increased to approximately 5 to 10 % of the final jacking force to take up the tendon slack and to
determine the zero position for measuring the extension and to check the gripping devices and the position and alignment of the
jacks. The load shall then be increased gradually to the full specified tensioning force while intermediate gauge readings and
extensions are recorded at regular intervals.
The final stage of tensioning shall be deemed to have been satisfactorily accomplished when all the following requirements have
been complied with:
1. The tendons have been tensioned to the required force.
2. The measured extension on individual tendons is within ± 6 % of the theoretical extensions.
3. The average variation between the measured and theoretical extensions of all the tendons in a structural member is less
than ± 3 %.
4. The release and/or pull-in is within ± 2,0 mm of the theoretical values.
Where the above conditions are not met individually and collectively, the Contractor shall immediately advise the Engineer and
obtain a ruling as to the procedure to be followed.
In the event of the tendon friction being too high, the Contractor may, subject to approval by the Engineer, inject an approved
lubricant into the sheath after first having detensioned the tendon.
The cost of the remedial and corrective measures and of the release and retensioning of tendons, which have been occasioned
by failure of the operations to meet the above requirements shall be for the Contractor's account.
After the tensioning has been accepted by the Engineer, the Contractor may cut off the tendons behind the anchorage as
described in Clause A13.5.7.3b).
f) Permanent protection and bonding of tendons
(i) General
After tensioning, all tendons shall receive permanent protection against mechanical damage and corrosion.
Internal tendons shall be protected and bonded to the structural member by cement grout or, when permitted by the Engineer, by
sand-cement grout. Where bond is not important, protection may be effected by the use of bitumen, petroleum-based
compounds, epoxy resins, plastics and similar products, all complying with the requirements of Clause A13.5.5.8 and subject to
approval.
Tendons located outside the structural section (i.e. external tendons) shall be encased with a dense concrete, dense mortar or
material sufficiently stable and hard, all subject to approval. The encasement shall be of the thickness shown on the drawings.
Where bonding of the tendon to the structural concrete is required, this shall be achieved by bonding the concrete encasement to
the structure with reinforcing steel as detailed on the drawings.
Protection and bonding of the tendons shall be effected within 7 days of the final tensioning of the tendons, or as specified on the
drawings, but shall not take place without the prior approval of the Engineer having been obtained.
After the permanent protection or bonding has been completed the anchorages shall be encased in concrete or grout which shall
be bonded to the old concrete with epoxy resin designed for this purpose, or shall be completely coated with a corrosion-resistant
material. The protection provided shall in all cases prevent the ingress of water or aggressive agents.
(ii) Preparation of ducts
Before permanent protection and/or bonding of tendons is effected, the following precautions shall be taken:
1. The cables shall be checked for blockages by water or compressed air, being injected.
2. Unlined ducts which are to be filled with grout shall be flushed with water to wet the concrete.
3. Temporary protection or lubricants which are incompatible with the permanent protection or bonding, shall be removed by
flushing the duct with water or an inert solution, or by any suitable approved method.
4. On completion of the above, any excess fluid shall be expelled from the ducts by means of compressed air or shall be
displaced by the protecting agent or grout, as may be relevant.
Any blockages, leakages or factors which in any way may affect the permanent protection or bonding shall immediately be
reported to the Engineer.
(iii) Mixing
1. Protecting agents
The mixing of protecting agents shall be strictly in accordance with the manufacturer's instructions.
2. Grout
The aggregate, if used, and the cement shall be measured by mass, and the water by mass or by volume.
The water: cement ratio by mass shall be as low as possible within the range between 0,36 to 0,45, and shall be consistent with
the fluidity requirements of Clause A13.5.5.7b).
Where an admixture is used, it shall be dissolved in a part of the mixing water before it is added to the grout.
Mixing shall be commenced by two-thirds of the cement being added to the greater part of the mixing water, and, if used, an
additive predissolved in part of the mixing water, and finally the remainder of the cement. Mixing shall continue for not longer
than 4 minutes after which the grout shall be continually agitated at slow speed throughout the injection operation.
Where aggregate is used in the grout mix, the word "cement" in the preceding paragraph shall be replaced by the term
"cement/aggregate component".

(iv) Injection
1. General
The injection of permanent protecting agents or grout shall not commence before approval has been granted that the work may
start.
Before injection commences all air shall be expelled from the injection equipment and hoses and all connections checked for
airtightness.
Injection shall take place from the anchorage or coupler, whichever is situated at the lower end of the cable.
Grout injection shall proceed without any interruption until the cable has been completely filled and closed off.
2. Protecting agents
The injection of protecting agents shall be strictly in accordance with the instructions, and with the equipment specified by the
manufacturer.
3. Grout
Immediately after mixing, and also during injection, the fluidity of the grout shall be tested at regular intervals in accordance with
Clause A13.5.5.9.
Injection shall be continuous at a rate of 6,0 m to 12 m per minute. As soon as grout with the original consistency flows from the
intermediate vent pipes they shall be successively closed. Injection shall continue until the grout flowing from the vent at the free
end is of the same consistency as that of the injected grout. At this stage the vent shall be closed and the final pressure or a
pressure of 5 bars, whichever is the greater, shall have been maintained on the grout column for 5 minutes before the valve at the
injection end is closed.
All vents shall be kept closed and supported vertically until the grout has finally settled. On vertical cables, a riser pipe with funnel
shall be fitted to the top anchor to ensure that the separated water migrate upwards and will not remain in the cable.
If an expanding agent is used in the grout mix, the air vents shall be re-opened after grouting to release any separated water, and
shall then again be closed.
Unless a retarder is used in the grout mix, the grout not used within 60 minutes of mixing shall be discarded.
During the course of grouting 100 mm cubes shall be made for testing in accordance with Clause A13.5.5.9. Whilst the grout is
being poured into the cube mould, the sides of the mould shall be slightly tapped to permit any entrapped air to escape.
All excess grout including expelled, spilt or waste grout shall be collected and disposed of in an approved manner. No grout shall
be allowed to flow over formed concrete surfaces in order to avoid permanent marking. Precautions shall be taken not to
discharge the escaping grout onto railway lines, public roads, rivers or private property.
If a blockage occurs during the course of grouting, the grouting shall be stopped before the maximum grouting pressure is
reached. The duct shall then be flushed out immediately and the blockage cleared.
Grouting shall not be carried out during very cold weather when the ambient air temperature drops below 5C. Care shall be
taken that the ducts are completely free from frost or ice before grouting commences after frosty weather.
A13.5.7.4 Loss of prestress

Any structural member which has lost all or part of its prestress through the failure or malfunctioning of any part of the prestressing component
may be rejected by the Engineer and shall be removed from the works unless approved remedial measures have been successfully carried out
on the member. No payment will be made in respect of such remedial work or loss suffered by the Contractor in this regard.
A13.5.7.5 Safety
Stressing operations shall be carried out under the direction of a competent person. Workers involved in prestressing shall be instructed in, and
follow safe work procedures. Appropriate eye protection shall be worn by all workers involved in grouting, stressing and cable trimming
operations.
During prestressing operations, workers shall be protected by guards or other suitable devices at the tensioning ends and anchoring points to
contain the flying strands and the strand wedges in the event of strand failure.
Welding, flame-torching or other similar operations shall not be permitted in the vicinity of prestressing strands unless proper care is taken to
protect the strands from sparks or other heat sources, and from stray electric currents.
Visual or audible signaling devices shall be provided and used in the area of tensioning operations to warn workers approaching the area.
Workers not directly involved in tensioning or de-tensioning operations shall be kept clear of the danger area and shall remain clear until
operations are completed and the visual or audible signals are turned off or removed.
Strand elongation and strand deflection shall be measured by a means which does not expose the workers to the risk of injury.
A13.5.8 WORKMANSHIP
The Contractor shall ensure that prestressing is done in accordance with the specifications and instructions of an ECSA Registered
Professional Engineer, and a copy of such information shall be available in the safety file on site while the work is being done.
Sheaths for prestressing tendons shall be placed and maintained in position within the following tolerances:
In the direction of the width of the member:
• For members of up to 200 mm in width ...................................................................................................................... ± 10 mm
• For members exceeding 200 mm in width ................................................................................................................... ± 20 mm
In the direction of the depth of the member:
• For members of up to 200 mm in depth ........................................................................................................... ± 0,025 x depth
• For members exceeding 200 mm in depth ...................... ± 0,010 x depth within the tolerance range of ± 5,0 mm to ± 25 mm.

B13.5 PRESTRESSING
CONTENTS
B13.5.1 SCOPE
B13.5.2 DEFINITIONS
B13.5.3 GENERAL
B13.5.5 MATERIALS
B13.5.8 WORKMANSHIP
B13.5.1 SCOPE
This Section covers the materials, equipment and work required for prestressing structural concrete members. Due to the specialised skills level
that is required for this activity, it is deemed not suitable for labour enhanced construction methods.
B13.5.2 DEFINITIONS
The provisions of Part A shall apply with no additional requirements.
B13.5.3 GENERAL

B13.5.5 MATERIALS


B13.5.8 WORKMANSHIP

C13.5 PRESTRESSING
(i) Preamble
None.
pay items.
C13.5.1 Prestressing tendons:
C13.5.1.1 Longitudinal tendons meganewton-metre (MN-m)
C13.5.1.2 Transverse tendons meganewton-metre (MN-m)
C13.5.1.3 Vertical tendons meganewton-metre (MN-m)

The unit of measurement shall be the meganewton-metre which is calculated as the product of the nominal tensile strength in megapascals of the
prestressing steel, the cross-sectional area of the tendon in square metres and the length of the tendon in metres between the faces of the
anchorages, as shown on the drawings. In the case of fan and loop anchorages the "length of the tendon" shall include the length of tendon
forming the loop or fan.
Where the Contractor provides an alternative prestressing system where the quantities exceed that of those shown on the drawings, the quantities
shown on the drawings shall be used for measurement.
The tendered rates shall include full compensation for preparing and submitting the drawings, supplying, storing, handling and protecting all
materials (excluding anchorages and couplers), fabricating, supporting and installing the cables; lubricating, permanently protecting and bonding the
tendons, for the using of all the equipment, as well as for all work and incidentals required for completing the work as specified.
C13.5.2 Anchorages and couplers:
C13.5.2.1 Anchorage at jacking end meganewton (MN)
C13.5.2.2 Anchorage at dead end meganewton (MN)

C13.5.2.3 Coupler at jacking end meganewton (MN))
C13.5.2.4 Coupler at dead end meganewton (MN))

The unit of measurement shall be the meganewton which is calculated as the product of the nominal tensile strength in mega pascals of the
prestressing steel and the cross-sectional area of the tendon in square metres, effectively anchored or coupled.
The tendered rates shall include full compensation for supplying, storing, handling, fabricating and protecting the complete anchorage or coupler
assembly, anchorage reinforcing, constructing the recesses for the anchorage or coupler, tensioning, anchoring and/or coupling, trimming the
tendon ends, using all the equipment, as well as for all work and incidentals required for completing the work as specified.
The coupler shall include the complete assembly consisting of the anchorage built into the first-stage construction and the part coupled to it.
The tendered rate for loop or fan anchorages shall exclude the cost of the length of tendon forming the loop or fan.
C13.5.3 Extra over item C13.5.2 for partially tensioning the tendons meganewton (MN)
The unit of measurement shall be the meganewton, which is calculated as for item C13.5.2.
The tendered rate shall include full compensation for the use of all equipment, as well as for all work and incidentals required for tensioning and
anchoring the tendons to the specified partial force.

D13.5 PRESTRESSING
CONTENTS
D13.5.1 SCOPE
D13.5.2 GENERAL
D13.5.1 SCOPE
D13.5.2 GENERAL
a) Prestressing strand: each parcel or cheese


Prestressing system:
a) Proven track record;
b) Compliance with an internationally recognised standard such as EN 13391.

13.6 BEARINGS
CONTENTS
A13.6.1 SCOPE
A13.6.2 DEFINITIONS
A13.6.3 GENERAL
A13.6.5 MATERIALS
A13.6.8 WORKMANSHIP

A13.6 BEARINGS
A13.6.1 SCOPE
This Section covers various items of work associated with the construction, supply and installation of bearings for structures. All bearings shall
be designed, manufactured and installed in accordance with European Standard EN 1337: “Structural Bearings.”
A13.6.2 DEFINITIONS
The following definitions shall apply to this Section:
Polytetrafluoroethylene chemical compounds used for sliding surfaces of Bearings (PTFE).
The Hardness of rubber used in Bearing is defined as International Rubber Hardness Degree (IRHD).
Elastomer - natural or synthetic rubber which has both viscosity and elasticity.
Large Elastomeric Bearings - these are bearings which can be subjected to a maximum vertical load of 3000 kN at ultimate limit state
Micaceous Iron Oxide (MIO) points are used as part of the paint systems for Bearings
Shear Modulus (G) is the ratio of shear stress to shear strain
Polychloroprene Rubber (CR) and Natural Rubbers (NR) are used in bearings.
A13.6.3 GENERAL
The bearings in this Section include simple bearing strips of roofing felt and rubber, elastomeric bearings reinforced with steel plates and
precision manufactured steel pot type, spherical, uplift and line rocker proprietary bearings.

A13.6.4.1 Design of elastomeric bearings
All bearings shall be designed to the European Standard EN 1337: Part 3 for Elastomeric Bearings.
a) Technical data
The following technical data for the elastomeric bearings will be specified on the drawings, and shall also be indicated on drawings prepared by
the Contractor for submission to the Engineer related to the specific type of bearing proposed:

(i) Design loads and deformations
The critical design-load combinations and co-existing rotations and horizontal displacements for each bearing or each group of
identical bearings.
b) Size and construction of bearing
The size and construction of a bearing shall be designated by
a x b x n(t) or D
Where
b = length of bearing in the transverse direction, in mm.
a = width of bearing in the span direction, in mm.
t = thickness of individual elastomer layers, in mm.
n = number of elastomer layers.
D = diameter of bearing.
The steel plates shall be encased in a 5,0 mm thick elastomer layer.
c) Hardness and type of elastomer
The IRHD hardness and type of elastomer, i.e. natural or synthetic rubber, from which the specified bearings are to be manufactured.
d) Identification
Each bearing shall be identified by a unique number
e) Alternative bearings
Where alternative bearings are offered by the Contractor, these shall be designed in accordance with the requirements of EN 1337 for the
loadings and deformations shown on the drawings.
Where a bearing consisting of a type of rubber is offered, which differs from that which is specified, the bearing shall be redesigned to make
provision for the variation in hardness and/or type of rubber.
A13.6.4.2 Design of proprietary bearings

a) Drawings and approval
All proprietary bearings shall be designed to the European Standard EN 1337: “Structural Bearings”.
Prior to manufacturing the bearings, the Contractor or his nominee shall submit the following information to the Engineer for consideration.
(i) The manufacturer's specification containing detailed information on the design standards, materials, manufacture and technical data.
(ii) Drawings complying with the provision in Chapter 1 showing the bearing construction and installation details.
(iii) Friction properties based on actual tests conducted on the relevant materials.
All bearings used in the permanent Works shall be subject to the approval of the Engineer and subject to a performance guarantee.
b) Technical data
The following technical data for the proprietary bearings will be supplied on the drawings, and shall also be supplied on the drawings prepared
by the Contractor for submission to the Engineer.
c) Design loads and movement
The maximum and minimum vertical loads and co-existing horizontal loads both at serviceability and ultimate limit state as well as the maximum
horizontal load and co-existing vertical load.
The maximum values in each direction of the reversible and irreversible movements and the rotation about each axis.
d) Mechanical fit
Mechanical fit on unidirectional and fixed bearings expressed as the maximum permissible slack (play) shall be smaller or equal to 1mm
between the shear transfer members of the bearing which are required to resist the applied horizontal loads.
e) Identification
Identification of each bearing by a unique number, data on the degree of freedom of movement (fixed, multi-directional or unidirectional
bearings) and the type of bearing (spherical, elastomer-pot, etc.) shall appear on each bearing. However, the direction of movement of the
bearing must correspond to the direction on the drawings.
f) Design
The bearings shall be designed to accept the specified load combinations in conjunction with the maximum eccentricity and rotation, without
overstressing any part in terms of working load requirements or exceeding the requirements for the serviceability limit.
Unless otherwise specified in the Contract Documentation or on the Drawings, the following shall be complied with:
(i) The maximum average stress on the projected area of the PTFE shall not exceed 45 MPa under ultimate effects and 30 MPa under the
permanent design load effect for the serviceability limit state. The maximum peak stress on the projected area of the PTFE shall not
exceed 55 MPa under all the design load effects and permanent design load effects for the serviceability limit state.
(ii) The maximum average contact stress and maximum edge stress on the concrete or mortar bedding shall not exceed 20 MPa and 25
MPa respectively.
(iii) The initial peak static coefficient of friction shall not exceed 0,06 and the final static coefficient of friction shall not exceed 0,04.

(iv) The max stress in the elastomer shall not exceed 25 MPa for the maximum serviceability limit state.
(v) The bearing shall be of such overall dimensions as to fit into the space allowed for its installation. Major alterations to the contiguous
members will not be considered.
(vi) Movements shall be considered at the ultimate limit state for all proprietary bearings.
A13.6.5 MATERIALS
A13.6.5.1 Bearings in structures
a) General
Unless otherwise specified, all the materials used for manufacturing the bearings shall comply with the requirements of EN 1337: Structural
bearings.
b) Roofing felt
Roofing felt shall be 3-ply and comply with the requirements of SANS 92 for type 1 roofing felt.
c) Elastomer
(i) General
The elastomer used in the manufacture of Elastomeric Bearings should be specified in the project documentation as either natural
rubber (NR) or chloroprene rubber (CR) as the raw polymer. Blending with up to 5 % of another polymer, which may be added to
aid processing, is permitted. No reclaimed or ground vulcanized rubber shall be used.
NOTE: Natural rubber bearings can be protected by a cover of polychloroprene, both parts vulcanized simultaneously.
(ii) Physical and mechanical properties of elastomer
The physical and mechanical properties of the elastomer shall comply with the requirements given in Table A13.6.5-1, depending
upon the raw polymer used. In case of a natural rubber bearing having a polychloroprene cover, the natural rubber does not have
to be tested for ozone resistance.
The polychloroprene compound for the cover shall meet the requirements for polychloroprene and the core shall meet the
requirements for NR, except for ozone resistance.
The frequency of the tests given in Clause 8 of EN 1337 – 3.
The specifications are given for moulded test pieces or samples taken from complete finished bearings. In this case they shall be
taken from the top and bottom surfaces or first internal layer, and from the internal layer at the centre of the bearing.

Table A13.6.5-1: Physical and mechanical properties of elastomer
Characteristics Requirements Test methods
Shore Hardness (IRHD) 60 ± 5

Shear Modules (MPa) (G) 0.9
Tensile strength (MPa)
Moulded Test Piece ≥ 16
Test Piece from bearing ≥ 14 ISO 37
Minimum Elongation at break (%) Type 2
Moulded Test Piece 425
Test Piece from bearing 375
Minimum Tear Resistance (kN/m)
CR ≥ 10 ISO 34-1
NR ≥ 8 Trouser
(Method A)
Compression Set (%) CR ≥ 15 ISO 815
24h ; 70 ºC NR ≥ 30 Ø29 x 12,5 mm
Spacer: 9,38 – 25 %
Accelerated Aging ISO 48
(Maximum change from unaged value) ISO188
- Hardness (IRHD)
NR 7 d, 70 ºC - 5 + 10
CR 3 d, 100 ºC ±5
- Tensile strength (%)
NR 7 d, 70 ºC ± 15
CR 3 d, 100 ºC ± 15
- Elongation at break (%)
NR 7 d, 70 ºC ± 25
CR 3 d, 100 ºC ± 25
Ozone Resistance No Cracks ISO 1431-1

Elongation : 30 % - 96 h
40ºC ± 2ºC
NR 25 pphm
CR 100 pphm)
d) Stainless steel sliding plates

The texture of the sliding surface of stainless steel plate used in conjunction with PTFE to form low-friction sliding surfaces shall be equal to or
better than 0,20 micrometer Ra in accordance with the requirements of BS 1134.
e) Stainless steel plates in elastomeric bearings
All plates in elastomeric bearings shall be manufactured from 3CR12 stainless steel and corners shall be rounded to a 10 mm radius or 10 mm
bevel. The plates shall be sand blasted to SA 2 to ISO 8501 to ensure adhesion of the elastomer layers.
The minimum plate thickness shall be 2,0 mm.
f) Stainless steel dowels and bolts
Stainless steel used for the manufacture of dowels and anchor bolts shall comply with the requirements of BS 970: part 4 for steel 316S16.
g) Proprietary mortars
Mortar beddings for seating the bearings shall be composed of an approved sand and either cement or epoxy resin of an approved proprietary
mortar. The mortar beddings shall obtain full strength before the bearings are loaded. The mortar shall comply with the following strength
requirements:
(i) Sand-cement mortar
The 7-day compressive strength of 100 mm cubes made from the mortar and cured in a moist atmosphere for the first 24 hours
and afterwards in water at 22°C to 25°C and shall be not less than 2,0 times the average contact stress under the bearing or 15
MPa whichever is the greater. The samples shall be prepared in accordance with SANS 5861-3 and tested in accordance with
SANS 5863.

(ii) Sand-epoxy resin mortar
The cured compressive cube strength of the mortar shall be not less than 2 times the average contact stress under the bearing, or
20 MPa, whichever is the greater. The 100 mm cube samples shall be prepared in accordance with SANS 5861-3 and tested in
accordance with SANS 5863.
(iii) Mortar Thickness under bearings
Mortars shall have a maximum thickness of 20 mm unless otherwise specified on the drawings.

The Contractor shall before construction commences, provide comprehensive details of all plant and equipment which shall be appropriate for
lifting, placing and installation of bearings.

A13.6.7.1 Concrete hinges
Concrete hinges shall be constructed in accordance with the details shown on the drawings.
Construction joints shall not be formed in the throat area. Where a joint is necessary, it shall be formed as a recess below the throat, level with
the top reinforcement mat. The width of the recess shall be slightly greater than that of the throat.
Care shall be taken to eliminate the formation of shrinkage cracks within the throat.
During construction, adequate bracing and support shall be provided to the satisfaction of the Engineer to prevent rotation in the throat from the
time of casting to completion of the structure incorporating the hinge. During the course of construction the hinge shall not be subjected to
conditions which will induce tensile stresses in the throat area.
Upon completion of the structural members incorporating the hinge, the space around the throat shall be filled and sealed with an approved
compressible material.
A13.6.7.2 Roofing felt

Roofing felt used as bearing strips shall consist of at least 3 layers of 3 ply roofing felt.
Where lubricated linings are specified, the roofing felt shall be saturated with used motor oil and then liberally dusted with graphite powder
before it is laid on the bearing surface.
A13.6.7.3 Proprietary bearings

a) General
This section covers custom-built bearings and bearings manufactured under license, except elastomeric bearings. Combined bearings,
consisting of an assembly of an elastomeric bearing in conjunction with a low-friction sliding or mechanical component shall fall under this
Clause.
Bearings shall be fitted with adaptor plates to facilitate removal for maintenance and replacement. Only where specifically stated on the
drawings or Contract Documentation may adaptor plates be omitted.
The Contractor shall base his tender on any bearing which complies with the specified requirements, provided that the efficacy of the bearing
has been verified by tests and successful previous use. Evidence hereof as well as information on the durability and suitability of the bearings
for the specified use shall be submitted to the Engineer for consideration together with a performance guarantee.
Details of the product guarantee shall be submitted with the tender and shall be in accordance with the requirements as set out in Chapter 1.
b) Manufacture
Unless otherwise specified in the Contract Documentation or on the Drawings, the following requirements shall be complied with:
(i) The IRHD of the elastomer disc in the pot type of bearing shall be 50 ± 5 or 55 ± 5. The elastomer shall be protected along the edge of
the disc by either a metal sealing ring or a capping ring moulded integrally with the disc along the perimeter.
(ii) The thickness of the elastomer disc shall not be less than 0,066 times its diameter.
(iii) The PTFE shall be not less than 3,0 mm thick and shall be recessed into the supporting base to a depth of 0,5 times the thickness of the
PTFE plus or minus ± 0,2 mm.
(iv) The minimum dimension of individual PTFE areas shall not be less than 50 mm and their spacing shall be such as to ensure the equal
distribution of stress throughout the contiguous members.
(v) The thickness of the stainless-steel sliding plate shall be not less than 1,25 mm. The plate shall be either recessed into or bonded to the
base and, in addition, riveted or bolted to the base. The edges of the plate shall be sealed to prevent the ingress of moisture between
the plate and the base.
(vi) The slack (play) between the shear transfer members of unidirectional and fixed bearings shall not exceed 2,0 mm, unless otherwise
specified.
(vii) Only silicone grease of an approved type shall be used as lubricant between the sliding surfaces.
(viii) The bearing shall be provided with tight- fitting seals to prevent the ingress of dust or deleterious matter onto the moving parts. The
seals shall be of an approved type and shall be sufficiently durable to last for longer than 50 years.
(ix) The assembled bearing shall be supplied with welded or bolted lugs or straps, temporarily securing the moving parts firmly in position to
ensure that no undesirable relative movement occurs before or during construction.
(x) The bearing shall be recessed into adaptor plates or bolted to flat plates where no recess is provided. All horizontal loads shall be taken on
the recessed flanges or holding down bolts on the adaptor plates
(xi) Anchor and holding-down bolts shall be of the material specified on the Drawings.
(xii) Corrosion protection of the exposed steel surfaces, with the exception of the stainless-steel sliding plate, shall be as follows:
1. Preparation of the surfaces by abrasive blasting to a finish equal to the Sa 3 finish of BS EN ISO 8501-01 medium profile.
2. Sprayed metal coating of the surface with zinc in accordance with the requirements of BS EN 22063, to a thickness of not less
than 100 microns.
3. Coating of the zinc-sprayed surfaces shall be within 4 hours with a sealer compatible with the zinc and the subsequent coat of
paint.
4. Application of a Zinc Rich Epoxy primer to 50 – 70 microns dft
5. Application of 2 coats of an Epoxy MIO undercoat to 100 microns mdft each.
6. Application of a final coat of a 2 component acrylic polyurethane of 50 microns mdft and of a dark grey colour.
7. Minimum total dry-film thickness 325 microns excluding sprayed metal coating.
Surfaces in contact with concrete shall receive only the treatment described in 1 and 2 above. Hot dip galvanizing may be permitted by the
Engineer to replace the Zinc metal spraying in 1 and 2 above, however the manufacturer shall allow for machining the surfaces as required.
Special care shall be taken to prevent flaking of the galvanized surfaces.
c) Dowels and guides
Where dowels and guides are used in conjunction with bearings they shall not complicate or prevent the removal of the bearings.
d) Storage and handling
The bearings shall at all times be stored under cover and clear of the ground, away from sunlight, heat, oils and chemicals deleterious to the
bearings. The bearings shall not be stacked in a manner or on a surface which will cause distortion of the bearings.
The bearings shall be handled with care to ensure that they are not subjected to impact loads or any other conditions which may be harmful.
e) Installation
The Contractor shall submit to the Engineer for his approval a detailed method statement including all materials and details for the installation of
Bridge Bearings.
The concrete surfaces of elements required to receive bearings shall comply with the requirements of Clause A13.2.2.2c). Plastering of the
surface will not under any circumstances be permitted.
Before the mortar bedding is constructed, the concrete surface shall be chipped back to expose the aggregate and leave a sound irregular
surface. Bonding of the mortar bedding to the concrete surface shall be in accordance with the manufacturer's recommendations and the
Engineer's instructions.
Unless otherwise shown on the drawings, the bearings shall be installed on a horizontal plane and shall be in full contact with the concrete and
bedding surfaces. In order to ensure full contact between the concrete and the bedding surfaces, the Contractor shall provide a method
statement for the system of grouting to be used.
The Contractor shall test the method statement using a mock-up of the bearing installation. After approval by the Engineer, the Contractor shall
use the same team who did the mock up test to install the bearings.
To accommodate soffit irregularities and camber in the case of precast members, the member shall be lowered onto an epoxy mortar layer on
top of the bearing. The member shall then be propped until the mortar layer has hardened into a wedge.
The bearings shall be accurately installed to the specified level, alignment and orientation, all within the construction tolerances set out in Clause
A13.6.8.1a) and the details shown on the drawings.
Where the bearing has long sliding plates, the latter shall be rigidly supported to prevent their being distorted under the weight of the wet
concrete and the construction loads.
Before the bearing is incorporated into the structure, it shall be cleaned to remove all deleterious substances and adhering matter, after which it
shall be wrapped in polyethylene sheeting and so sealed as to prevent the ingress of mortar and/or slush onto the bearing during the course of
construction.
After installation, the polyethylene wrapping shall be removed, the bearing and the space around the bearing thoroughly cleaned and the lugs
removed as prescribed by the Engineer.
On completion of installation of proprietary bearings, the Contractor shall submit to the Engineer a certificate from the manufacturer or supplier
of the bearings certifying acceptance of the installation in accordance with EN 1337. The issuing of such a certificate shall not relieve the
Contractor of his responsibility under this contract. Payment for the inspection of the bearings by the manufacturer or supplier and the issuing of
the certificate will be made under Section C20.1 of Chapter 20.

A13.6.8 WORKMANSHIP
The tolerances given below shall be the maximum permissible deviations from the specified dimensions, levels, alignment, positions, etc.,
a) Bearings
Bearings for structures shall be installed to within 5,0 mm of the position shown on the drawings and to within 2,0 mm of the required level.
Horizontal surfaces of Bearing Plinths shall comply with the tolerances as set out in EN 1337-3 Section 7.1.
Dimensional tolerances for elastomeric bearings shall comply with the requirements of EN 1337-3 Section 6.
A13.6.8.2 Inspection and testing

a) Elastomeric bearings
(i) When requested by the Engineer, the Contractor shall submit test certificates from an approved, independent testing authority to show that
the respective materials comply with the specified requirements, or a certificate from the patent holder or designer certifying that the
manufactured item complies in all respects with the relevant product specifications. All these tests shall be carried out in accordance with
the requirements of EN 1337-3 Section 8.
(ii) On completion of the manufacture of the bearings, the Contractor shall submit bearings selected by the Engineer, or specially
manufactured bearings to serve as samples as authorised by the Engineer, to an independent testing authority for testing.
The testing facilities of the manufacturer or supplier may be used if so approved and on condition that the tests are conducted in the
presence of the Engineer.
The Engineer will determine which tests are to be conducted, and the tests shall comply with the appropriate requirements of Clause
A20.1.5.6a) of Chapter 20. Payment will be made under Section C20.1 of Chapter 20 for these tests, for bearings damaged, and for sample
bearings.
Copies of test results and certificates for the abovementioned tests shall be submitted by the Contractor to the Engineer in good time to
enable the Engineer to assess the information before the bearings are installed.
(iii) Before the bearings are dispatched to the site of the works, each bearing, with the exception of large bearings as defined in Clause
A13.6.2, shall be subjected simultaneously to a vertical load equal to 150 % of the maximum design load, and to a shear distortion equal to
150 % of the maximum design value. The bearings shall be visually inspected for defects by the Engineer or his nominee and shall not at
any stage under this test show any cracks visible to the naked eye or any other defects. The cost of this testing shall be included in the
rate tendered for under Section C20.1 of Chapter 20.
The Engineer may instruct that 1 or more bearings of each consignment shall be cut open with a view to a visual assessment of the
bonding and the thickness of the elastomeric layers. Payment for these bearings shall be paid for under payment item C13.6.1.
Large bearings shall also be tested by cutting them into halves or quarters in accordance with EN 1337-3. The test results shall then be
factored to ensure that the loads obtained meet the requirements of the design.
(b) Proprietary bearings
The Engineer may require tests to be conducted to verify compliance of the bearing with the EN 1337 specifications and/or its satisfactory
performance under the design loads. Payment for this testing will be made under Section C20.1 of Chapter 20.
Test certificates of all the tests conducted shall be submitted to the Engineer.
The Contractor shall give the Engineer at least 14 days' notice prior to final assembly of the bearings to enable the Engineer to inspect the
bearings at the factory.
Under no circumstances shall bearings be taken apart and reassembled on the site, except where it is an unavoidable feature of the installation
procedure, in which case the dismantling, installation and reassembly shall be under the supervision of qualified personnel.
Rehabilitation, modification and repair work to bearings shall be carried out only in the factory or in an Engineering works approved by the
Engineer.

B13.6 BEARINGS
CONTENTS
B13.6.1 SCOPE
B13.6.2 DEFINITIONS
B13.6.3 GENERAL
B13.6.5 MATERIALS
B13.6.8 WORKMANSHIP
B13.6.1 SCOPE
This Section covers various items of work associated with the construction, supply and installation of bearings for structures. This Section is of a
specialist nature and is not suitable for labour enhanced work.
B13.6.2 DEFINITIONS
B13.6.3 GENERAL

B13.6.5 MATERIALS


B13.6.8 WORKMANSHIP

C13.6 BEARINGS
(i) Preamble
None.
pay items.
C13.6.1 Bearings:
C13.6.1.1 Bearings (description of each type and class) number (No)

C13.6.1.2 Provision of Engineering drawings of proprietary bearings and certification after installation, lump sum
by an ECSA Registered Professional Engineer or Technologist.
The unit of measurement shall be the number of complete bearings of each type and class installed.
The tendered rate shall include full compensation for supplying all the materials, including anchor bolts and/or dowels, constructing the bedding,
manufacturing the bearings, transporting, handling and storing, and all labour, equipment and incidentals required for installing the bearings
complete as detailed. The tendered rate shall also include for the provision of Engineering drawings and certification after installation by an
ECSA Registered Professional Engineer or Technologist. Payment shall only be made for the Engineering drawings after the submission of the
construction record drawings of the bearings. Payment shall be made in 2 stages 50 % on submission and approval of the Bearings and 50 %
on the submission of the record drawings of Bearings.
C13.6.2 Concrete Hinges
C13.6.2.1 (Description of hinge measured per metre) metre (m)
C13.6.2.2 (Description of hinge measured by number) number (No)

The unit of measurement shall be either the metre of complete hinge of each type manufactured and installed or the number of complete hinges
of each type manufactured and installed.

The tendered rates shall include full compensation for supplying all materials, including formwork, manufacturing the hinges, transporting,
handling and storing, sealing the hinges, and all labour, equipment and incidentals required for installing the hinges complete as detailed.
C13.6.3 Bearing strips (description of the material and number of Layers) square metre (m2)
The unit of measurement shall be the square metre of bearing area lined with the specified material irrespective of the number of layers placed
The tendered rate shall include full compensation for supplying all the materials, transporting, handling and storing, and all labour and incidentals
required for installing the bearing strips complete as detailed.
C13.6.4 Dowels or guides (description of each type) number (No)

The unit of measurement shall be the number of dowels/guides of each type installed.
The tendered rate shall include full compensation for supplying all materials, including anchor bolts, manufacturing the dowels/guides
transporting, handling and storing, and all labour, equipment and incidentals required for installing the dowels/guides complete as detailed.
C13.6.5 Specialist proprietary bearings:
C13.6.5.1 Prime cost sum allowed for purchasing and taking delivery of bearing prime cost sum
C13.6.5.2 Percentage on prime cost sum for charges and profit percentage (%)
Payment for purchasing and taking delivery of proprietary bearings, complete with anchor bolts and/or dowels, shall be in accordance with the
provisions of the general conditions of contract.
C13.6.6 Installing the proprietary bearings (description of each type, and state class) number (No)
The unit of measurement shall be the number of complete bearings of each type and class installed.
The tendered rate shall include full compensation for supplying all the materials not covered under item C13.6.5, constructing the bedding,
transporting, handling and storing, and all labour, equipment and incidentals required for installing the bearings complete as detailed.
The tendered rate shall be final and binding, irrespective of the type or make of bearing finally installed.

D13.6 BEARINGS
CONTENTS
D13.6.1 SCOPE
D13.6.2 GENERAL
D13.6.1 SCOPE
D13.6.2 GENERAL
The Contractor shall within 28 days before manufacture of the Bearings submit to the Engineer conformance documentation related to the
specifications. All products used in the manufacture and installation of Bridge bearings shall be in compliance with the specifications contained in
Section A13.6 and EN 1337.
Compliance documentation shall be provided for:
a) Carbon Steel
b) Stainless Steel
c) Natural Rubber (NR)
d) Synthetic Rubber (Polychloroprene) (SR)
e) PTFE
f) Epoxy Adhesives
g) Epoxy Mortars

The design and installation of proprietary bearings shall require a warranty of 25 years to be supplied by the Contractor. The format of this
warranty shall be as per Form D13.6.2 hereafter. A full set of drawings of the proprietary bearings shall be submitted together with certificates of
all tests carried out in accordance with the requirements of EN 1337.Certification of the installation by a suitably experienced ECSA Registered
Professional Engineer or Technologist is also required together with the warranty submitted with the taking over certificate.
D13.63.2 Performance specifications


Form D13.6.2
WARRANTY FOR DESIGN, MANUFACTURE AND INSTALLATION OF PROPRIETARY BRIDGE BEARINGS
ON (CONTRACT NUMBER AND DESCRIPTION)
DESCRIPTION DETAILS
Bridge Number
Name and Address of

Contractor
Name of Contact Person
Name and Address of

Manufacturer
Name and Address of

Installer
Date of Manufacture
Date of Installation
Duration of Warranty
Start date of Warranty
End date of Warranty
The Contractor, Manufacturer and Installer hereby warrant that the above bearings will perform satisfactorily in terms of workmanship and
durability, and that the bearings have been installed in accordance with the patent holders requirements and as set out in the specifications and
on the drawings for each particular bearing.
This warranty is for 25 years from the completion date of the Main Contract for the project.
In the event that the performance of the bearings is not in accordance with this warranty due to materials or workmanship defects, the
Contractor undertakes to rectify the bearings within 90 days of receiving the instruction to do so by the Employer.
The bearings shall be completely replaced including, supply and installation including all other costs associated thereto (i.e. Traffic
Accommodation, jacking, closure of the road and bridge as agreed to by the Employer) to the satisfaction of the Engineer.
SIGNED ON BEHALF OF CONTRACTOR: ____________________________________________________________________
SIGNED ON THIS THE ____________ DAY OF _______________________ IN THE YEAR ______________________________
on behalf of: _________________________________________________________________________________
Address: _________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Telephone No: _________________________________________________________________________________
SIGNED ON BEHALF OF MANUFACTURER: ___________________________________________________________________
on behalf of: _________________________________________________________________________________
Address: _________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Telephone No: _________________________________________________________________________________
SIGNED ON BEHALF OF INSTALLER: ____________________________________________________________________
on behalf of: _________________________________________________________________________________
Address: _________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Telephone No: _________________________________________________________________________________
WITNESS:
Signature: _________________________________________________________________________________
Name: _________________________________________________________________________________
Address: _________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Telephone No: _________________________________________________________________________________

13.7 JOINTS
CONTENTS
A13.7.1. SCOPE
A13.7.2 DEFINITIONS
A13.7.3 GENERAL
A13.7.5 MATERIALS
A13.7.8 WORKMANSHIP

A13.7 JOINTS
A13.7.1 SCOPE
This Section covers the supply and installation of all permanent joints which will permit relative movement between contiguous structural
members.
A13.7.2 DEFINITIONS
The following definitions shall apply to this Section.
Joint Termination - shall consist of the end treatment of a joint at a barrier, wall, soffit, parapet or sidewalk kerb.
Thermoplastic sealants - thermoplastic material has a high concentration of polymers with amorphous structures and excellent elasticity.
These sealants can be either hot poured or cold applied.
International Rubber Hardness Degree - refer to Clause A13.6.2. The hardness of rubber used in joint glands is defined as international
Rubber Hardness Degree IRHD
Polyethelene Tape - polyethelenes are types of polymers which are thermoplastic in nature
Agrément South Africa - an objective, independent agency which evaluates the fitness-for-purpose of non-standard construction products.
A13.7.3 GENERAL
This Section covers all types of joints in structures including horizontal and vertical joints in walls and slabs and bridge deck expansion joints.
Cover plates at the termination of bridge joints shall always be provided.
Proprietary bridge joints shall have Agrément South Africa certification. The certification shall include the Roadway / Footwalk / Barrier interface
as part of the complete Joint System.
Joint terminations in Roadway Joints shall always be constructed as part of all expansion joints in the roadway.


the Engineer.


A13.7.4.1 Design and manufacture of proprietary joints
The expansion joint shall be designed to withstand the movements, displacements and rotations specified on the design drawings in conjunction
with the loads described in the code of practice adopted for the design of the structure without exceeding in any member the requirement for
serviceability limit state. Any strengthening of the supporting member required to resist forces imparted by the joint to the structure shall be for
the Contractor's account.
The specified movements, displacements and rotations shall be withstood without the efficacy or riding quality of the road being impaired.
The joint shall be vibration free, resistant to mechanical wear and other forms of abrasion, and shall resist corrosion. shall have good riding
quality characteristics, shall be highly skid resistant, and silent, also of watertight construction or have provision for the disposal of water, debris
or grit collecting in the joint. The construction of the joint shall facilitate easy inspection, maintenance and repair.
Corrosion protection of all the steel surfaces, with the exception of the stainless-steel section, shall be as follows:
a) Preparation of the surfaces by abrasive blasting to a finish equal to the Sa 3 finish of BS EN ISO 8501-01 medium profile.
b) Sprayed metal coating of the surface with zinc in accordance with the requirements of BS EN 22063, to a thickness of not less than 100
microns. Steel sections may also be hot dipped galvanized in accordance with the requirements of SANS 1391 part 1 for Zn 150 coverage.
c) Coating of the zinc-sprayed or galvanized surfaces shall be within 4 hours with a sealer compatible with the zinc and the subsequent coat
of paint.
d) Application of a Zinc Rich Epoxy primer to 50 – 70 microns dft
e) Application of 2 coats of an Epoxy MIO undercoat to 100 microns mdft each.
f) Application of a final coat of a 2 component acrylic polyurethane of 50 microns mdft and of a dark grey colour.
g) Minimum total dry-film thickness 325 microns excluding sprayed metal coating.
h) All proprietary joints shall have a joint termination into the barrier, parapet or sidewalk kerb which shall be turned up to an adequate height
such that it shall sustain the water tests as specified elsewhere herein.
i) Cover plates in bariers, parapets and sidewalk kerbs shall be manufactured from nonmetallic materials as specified on the drawings.
j) All fixing systems of the nonmetallic cover plates to the concrete surfaces shall be stainless steel.
Prior to manufacture of the joints, the Contractor shall submit for approval detail drawings in accordance with the requirements of chapter 1 for
each expansion joint. The design drawings shall be signed off by an ECSA Registered Professional Engineer or Technologist before
manufacture and shall also be handled in with the record drawings of the structure.
The expansion joints delivered at the site shall be suitably marked to show clearly the sequence and position of installation.
A13.7.5 MATERIALS
A13.7.5.1 Joints in structures
a) General
All materials used in forming, constructing and sealing permanent joints as well as all proprietary or custom-built expansion-joint assemblies
shall be subject to the approval of the Engineer.
b) Joint filler
Joint filler shall consist of sheets or strips of the following materials complying with the requirements of the relevant specifications listed:
Bitumen-impregnated fibreboard and bitumen - impregnated corkboard – US Federal Specification HH- F-341F or AASHTO Specification M213.
Resin-impregnated corkboard U S Federal Specification HH-F-341F.
Flexible foams of expanded polyethylene, polyurethane, PVC or polypropylene AASHTO Specification.

Rigid foams of expanded polyethylene, polyurethane or polystyrene BS 4840 or BS 3837.
Other joint filler materials may be used if approved by the Engineer after he has been furnished with full specifications and information by the
Contractor.
c) Sealants
Thermoplastic hot-poured sealants shall comply with the requirements of US Federal Specification SS-S-1401B, BS 2499 or AASHTO
Specification M173. The sealants shall be of the rubberised bituminous type containing a minimum of 20 % natural or synthetic rubber.
Thermoplastic cold-applied sealants shall comply with the requirements of US Federal Specification SS-2-200E(2). The sealant shall be of the
rubberised bituminous type containing a minimum of 20 % natural or synthetic rubber.
Thermosetting chemically curing sealants shall comply with the requirements of ASTM C.920 or BS 4254.
The final IRHD hardness of the sealant shall be 20 ± 5.
Silicone sealants shall comply with the requirements of Clause A6.1.5.7c) of Chapter 6.
d) Waterstops
Waterstops shall be of natural rubber or flexible PVC and of the type specified or shown on the drawings.
Natural-rubber waterstops shall comply with the requirements of CKS 388.
Flexible PVC rubber waterstops shall comply with the requirements of CKS 389.
e) Accessory material
(i) Primers
Where a primer is to be used in conjunction with the sealant, it shall be of the prescribed proprietary material.
(ii) Bond breakers
Polyethylene tape, coated paper, metal foil or similar material may be used where bond breakers are required.
(iii) Backup material
Backup material shall consist of a compressible material of correct width and shape to ensure that, after installation, it will be in
approximately 50 % compression and the sealant can be formed to the specified depth.
Backup materials shall be compatible with the sealant used. Material containing bitumen or volatiles shall not be used with
thermosetting chemically curing sealants.
f) Joint terminations
Joint terminations shall be constructed of the same materials as the roadway joint and form a watertight monolithic system at the interface with
the barrier, wall, parapet and sidewall kerbs.
g) Cover plates
Cover plates at the termination of bridge deck joints shall be manufactured from fibre reinforced approved UV resistant nonmetallic materials.
Cover plates shall have a minimum thickness of 6,0 mm and specifications and drawings of cover plates shall be submitted to the Engineer for
approval. Anchor bolts and washers shall be of stainless steel grade x10CvNi18-8Co.05-0.155=0.015 which complies with the requirements of
BS EN 10088 part 1.

The Contractor shall before construction commences, provide comprehensive details of all plant and equipment which is appropriate for lifting,
placing and installation of bridge deck expansion joints.

A13.7.7.1 Filled and unfilled joints
a) General
Wherever polystyrene or similar material susceptible to damage is used for forming joints, it shall be lined with a hard surface on the side to be
concreted. The hard surface shall be sufficiently resilient to ensure that the joint and surfaces can be formed free from defects.
b) Filled joints
Filled joints shall be accurately formed to the dimensions shown and with the filler material specified on the drawings. The filler shall be secured
in position not to displace during concreting or thereafter if the filler is to remain permanently in the joint.
Where the removal of the filler is required, it shall be done prior to the installation of the proprietary joint.
c) Unfilled joints
Unfilled joints shall be accurately formed to the dimensions given on the drawings, and all external corners chamfered or rounded for at least 5,0
mm. The concrete face against which the fresh concrete is placed shall be treated in good time with an approved bond breaker.
d) Concrete nosings forming the edges of expansion joints shall be constructed as follows:
After the concrete in the structural member has hardened sufficiently, the protruding ends of the reinforcing steel shall be bent flat onto the
concrete surface of the formed recess.
Before the asphalt surfacing is laid, the recess shall be filled with well-compacted crusher run, sand or weak mortar. The Contractor shall
ensure that the concrete surfaces of the recess and the reinforcing steel are not contaminated with bituminous agents. The asphalt surfacing
shall then be laid continuously over the joint.
The asphalt surfacing shall be parallel cut with a diamond saw blade to correspond to the width of the nosing and all material shall be removed
from the nosing recess. The concrete surfaces of the recess shall then be roughened to expose the aggregate and leave sound, irregular
surfaces. The reinforcing steel shall then be bent, fixed and placed as shown on the drawings.
The prepared concrete surfaces of the recesses shall be treated as specified in Clause A13.4.7.11g)(ii), immediately before the concrete
nosings are cast. Opposite concrete nosings separated by a joint filler strip as specified, shall be cast simultaneously in accordance with Clause
A13.4.7.11g)(iii) and compacted by vibrator. The nosing shall be screeded flush with the asphalt surfacing and be given a class U2 surface
finish.
Curing shall be in accordance with method (6) of Clause A13.4.7.11h).
The exposed corners of the nosings shall be ground to a 10 mm chamfer.
After the joint has been sealed, the wearing surface of the nosings shall be treated with a bituminous primer to the satisfaction of the Engineer.
Unless otherwise specified, traffic shall not be permitted to pass over the joint before the concrete in the nosing has aged for at least 10 days.
Unless otherwise indicated on the drawings, the concrete used in the construction of the nosings shall be class C32/40 with a 13 mm aggregate
and shall have a slump of not less than 50 mm and not exceeding 75 mm.
Concrete nosings shall be constructed under the direct supervision of experienced and skilled personnel.
A13.7.7.2 Asphaltic plug proprietary type expansion joint systems

Asphaltic Plug proprietary type expansion joint systems, shall be constructed in accordance with the details on the drawings and the
specifications and instructions of the licensees which are to be submitted to the Engineer.
A13.7.7.3 Sealing the joints

a) General
Sealed joints shall be made watertight over the full length of the joint, including the full height of the kerbing, unless otherwise prescribed in the
Unless a waterstop is equipped with an effective watertight interlocking system for joining sections, all joints in waterstops shall be bonded or
fused to have a tensile strength of at least 50% of that of the unjointed material. At intersections and abrupt changes of direction, waterstops
shall be jointed with prefabricated junction pieces.
Restrictions on joint width and on the temperature at the time of installing the sealant or seal will be shown on the drawings. In the absence of
such restrictions on the drawings, and unless otherwise specified, installation shall be carried out only within the temperature range between 5°
C and 30°C.
b) Preparing the joints
Where required joints shall be sawn at a suitable time so as to avoid edge spalling or ravelling.
After the temporary filler material has been removed or the excess concrete has been broken out, the inside faces of the joint shall be wire-
brushed or sand-blasted to remove all laitance and contaminants. The joint shall then be cleaned and blown out with compressed air to remove
all traces of dust. Solvents shall not be used for removing contaminants from the concrete and porous surfaces.
The Contractor shall ensure that primers are applied only to surfaces which are absolutely dry. The primer shall be applied strictly in
accordance with the manufacturer's instructions. Unless otherwise specified, the primer shall be applied within the temperature range of 10°C
and 40°C and the sealant shall be applied after the curing period of the primer and within the period when the primer remains active.
c) Sealants
Sealants shall be applied strictly in accordance with the manufacturer's instructions by a person skilled in the use of the particular type of
sealant. Trapping of air and the forming of voids in the sealant shall be avoided. The sealant shall be finished to a neat appearance to the
specified depth.
Thermoplastic hot-poured sealants shall not be poured into the joints when the temperature of the joint is below 10°C. The safe heating
temperature shall not exceed the specified pouring temperature by more than 10°C.
Two-part thermosetting chemically curing sealants shall not be applied after expiry of the specified pot-life period which commences once the
base and activator of the sealant have been combined.
d) Waterstops
Waterstops shall be securely and accurately located in position so that they will not be displaced or deformed during construction.
A13.7.7.4 Proprietary expansion joints

a) General
The use of all types of proprietary expansion joint shall be subject to approval of the Engineer.
b) Dimensions
The Contractor shall note the overall dimensions of the expansion joints and the limiting dimensions of that portion of the concrete structure
which is to accommodate the joints. No alterations to the concrete which will be visible in the final structure or major re-arrangement of the
prestressing anchorages, will be permitted in order to accommodate joints of excessive size.

All joints to be installed skew shall be accurately dimensioned to ensure compliance with the requirements of Clause A13.7.7.4c).
Unless otherwise specified, proprietary expansion joints shall include the complete expansion-joint assembly, traversing the entire roadway,
kerbs, sidewalks and median, and shall include the joint terminations and barrier, parapet and sidewalk kerb nonmetallic cover plates as well as
the drainage system to drain the expansion joint
c) Installing the expansion joints
All deck expansion joints shall be installed by approved specialist subcontractors only. Installed deck expansion joints shall have the following
guarantees which shall be applicable from the date of the taking over certificate for the periods as prescribed hereunder.
Proprietary joints - 25 years
Asphalt plug type joints - 15 years
Elastomeric glands - 15 years
The guarantee provided shall include the nosings and the joint Roadway / Footwalk / Barrier interface and all components which make up the
joint system
Proprietary deck expansion joints will only be considered for use if the manufacturer has obtained Agrément South Africa certification.
No expansion joint or part thereof shall be installed prior to the construction of the final surfacing, unless otherwise approved.
The joint manufacturer and installer shall take full account of the reinforcement in the structural element into which the joint system is to be
installed. No indiscriminate cutting of existing reinforcement in joint recesses shall be permitted.
• The expansion joint shall form an even surface with the road surface on either side or the deviation across and along the expansion
joint shall comply with the requirements of Chapter 5 for surface regularity measured by ordinary straight-edge.
On completion of the installation of proprietary expansion joints, the Contractor shall submit to the Engineer a certificate from the manufacturer
or supplier of the joints, certifying acceptance of the installation. Notwithstanding the issuing of such certificate, it shall not relieve the Contractor
of his responsibility under the contract. Payment for the inspection of the joints and the issuing of the certificate by the manufacturer or supplier
will be made under Section C20.1 of Chapter 20.
A13.7.8 WORKMANSHIP
The joint assemblies shall be constructed within a tolerance of ± 5,0 mm for all dimensions. The alignment shall not deviate from the true
alignment by more than 10 mm in any place, nor shall other alignment deviate by more than 5,0 mm from the true alignment over a length of 5,0
m.
A13.7.8.2 Inspection and testing

When ordered by the Engineer, the Contractor shall submit test certificates issued by an approved, independent testing authority to confirm that
the respective materials in joint systems comply with the specified requirements, or a certificate by the patent holder or designer certifying that
the manufactured item complies in all respects with relevant product specifications.
A13.7.8.3 Water testing of joints

The water shall be ponded and maintained to a minimum depth 150 mm above the top of the joints at the lowest kerb or a minimum of 100 mm
elsewhere for a period of one hour each.
The testing should follow the installation of various sections of joints to take advantage of the existing traffic accommodation and each test shall
cover the length of each joint installed. (Generally, the half width of the bridge).
The Engineer has the right to order any additional water tests to prove the joint should this be required at his sole direction.

B13.7 JOINTS
CONTENTS
B13.7.1 SCOPE
B13.7.2 DEFINITIONS
B13.7.3 GENERAL
B13.7.5 MATERIALS
B13.7.8 WORKMANSHIP
B13.7.1 SCOPE
This Section covers the supply and installation of all permanent joints which will permit relative movement between contiguous structural
members. Complex joints are deemed to be of a specialist nature and hence not suitable for labour enhanced work.
B13.7.2 DEFINITIONS
B13.7.3 GENERAL

B13.7.5 MATERIALS


B13.7.8 WORKMANSHIP

C13.7 JOINTS
(i) Preamble
None.
restricted areas. Any additional costs associated with working in confined or restricted areas shall be deemed to be included in the
standard applicable pay items.
km and for labour enhanced construction, less than and up to 50 m.
8. For all Works performed, precautionary measures required in terms of the Occupational Health and Safety Act (Act 85 of 1993) and the
latest amendments thereof as well as the latest Construction Regulations shall be deemed included in the rates tendered for the relevant
products.
C13.2.1, C13.2.2, C13.2.3 and
Filled joints C13.7.21 and C13.7.2.2
C13.2.4 - All applicable items
C13.2.1, C13.2.2, C13.2.3 and
Unfilled joints C13.7.3.1 and C13.7.3.2
C13.2.4 - All applicable items
Expansion joints C13.7.10.1 and C13.7.10.2 C13.2.6 - All applicable items
C13.7.1 Expansion joints:
C13.7.1.1 (Description of joint measured per metre) metre (m)
C13.7.1.2 (Description of joint measured by number) number (No)

The unit of measurement shall be either the metre of complete joint between the kerbs of each type supplied and installed or the number of
complete joints of each type supplied and installed excluding the non-metallic coverplates.
The tendered rates shall include full compensation for supplying all materials, transporting, handling and storing, and all labour, equipment,
shaping the recesses, and incidentals required for installing the expansion joint complete in accordance with instructions (see notes 1 and 2
below). The joint measured shall be the complete joint shown on the drawings excluding the joint termination details, recesses and cover plates
at the barriers, parapets and sidewalks.

The tendered rates shall include full compensation for supplying all the materials, manufacturing the expansion joint, transporting, handling and
storing, and all labour, equipment, shaping the recesses, and incidentals required for installing the expansion joint complete in accordance with
instructions (see notes 1 and 2 below).
The tendered rate for items C13.7.1.1 and C13.7.1.2 shall also include for water test required to prove the joint. The tendered rate shall include
full compensation for providing the pond of water and maintaining its depth of 150 mm for the full one hour period and clearing away the
ponding materials on completion.
C13.7.2 Filled joints:
C13.7.2.1 (Description of joint and thickness of joint filler for joints measured per square metre) square metre (m²)
C13.7.2.2 (Description of joint and thickness of joint filler for joints measured per metre) metre (m)
The unit of measurement shall be the square metre of filled joint calculated from the surface area of the joint. Where the filled joint is 150 mm or
less in depth, the unit of measurement shall be the metre of filled joints measured along the joint centre line. Concrete surfaces formed prior to
the construction of the final surface for completing the filled joint shall be measured under item C13.2.1, C13.2.2, C13.2.3 or C13.2.4, as may be
applicable.
The tendered rates shall include full compensation for supplying and installing the joint filler and all materials not covered under item C13.7.4,
and for all labour and incidentals required for completing the filled joint as prescribed.
The tendered rate for items C13.7.2.1 and C13.7.2.2 shall also include for water test required to test the joint. The tendered rate shall include
full compensation for providing the pond of water and maintaining its depth of 150 mm for the full one hour period and clearing away the
ponding materials on completion.
C13.7.3 Unfilled joints:
C13.7.3.1 (Description of joint for joints measured per square metre) square metre (m²)
C13.7.3.2 (Description of joint for joints measured per linear metre) metre (m)
The unit of measurement shall be the square metre of unfilled joint, calculated in accordance with the joint area. Where, however, the depth of
the joint is 150 mm or less, the unit of measurement shall be the metre of unfilled Joint measured long the joint centre line. Concrete areas
formed before the final surface is constructed to complete the unfilled joint, shall be measured under items C13.2.1, C13.2.2, C13.2.3 or
C13.2.4, as may be applicable.
The tendered rates shall include full compensation for providing and applying the bond breaker and also for the labour and incidentals required
for completing the unfilled joint as prescribed.
C13.7.4 Sealing joints with:
C13.7.4.1 Sealant (description of joint, sealant and size) metre (m)
C13.7.4.2 Waterstop (description of joint, waterstop and size) metre (m)

The unit of measurement shall be the metre of sealant, seal or waterstop of each type installed.
The tendered rates shall include full compensation for supplying all materials, forming or cutting the concrete to the required shape and size, all
labour, equipment and incidentals required for sealing the joint complete in accordance with the prescriptions, and for all waste materials (see
note 2 below).
C13.7.5 Supply and installation of Agrément South Africa certified proprietary expansion joints
C13.7.5.1 Claw and other modular joints in nosings
(a) Type of joint and movement range specified metre (m)
(b) Type of joint and movement range specified metre (m)
C13.7.5.2 Asphaltic plug type joints
(a) 150 x 50 mm metre (m)
(b) 300 x 50 mm metre (m)
(c) 400 x 75 mm metre (m)

(d) 500 x 75 mm metre (m)
(e) 500 x 100 mm metre (m)
(f) (other dimensions as specified) metre (m)
(g) Extra over for variation in joint depth of asphaltic joints litre (lit)
C13.7.5.3 Provision of Engineering Drawings of proprietary joints and certification after installation by lump sum
an ECSA registered professional Engineer of technologist
The unit of measurement shall be the metre of complete joint inclusive of concrete or elastomeric nosings between the kerbs of each type
installed excluding the joint terminations and nonmetallic coverplates.
The tendered rates shall include full compensation for supplying all materials, transporting, handling and storing, and all labour, equipment,
shaping the recesses, and incidentals required for installing the expansion joint complete in accordance with instructions (see notes 1 and 2
below). The joint measured shall be the complete joint shown on the drawings excluding the joint termination details, recesses and cover plates
at the barriers, parapets and sidewalks. Payment for the Engineering drawings shall only be made after the submission of the construction
record drawings of the joints.
The tendered rate for all the sub items shall also include for water test required to prove the joint. The tendered rate shall include full
compensation for providing the pond of water and maintaining its depth of 150mm for the full one hour period and clearing away the ponding
materials on completion.
The tendered rate shall be final and binding, irrespective of the type or make of joint finally installed.
C13.7.6 Joint terminations in:
C13.7.6.1 Barriers and Parapets (type of joint indicated) number (No)
C13.7.6.2 Sidewalks (type of joint indicated) number (No)

The unit of measurement shall be the number of each type of joint termination installed.
The tendered rate shall include full compensation for all supplying materials transporting, handling and storing, and all labour, plant and
equipment to form the recesses and install the joint terminations as specified and indicated on the drawings.

C13.7.7 Cover plates (non-metallic) in barriers, parapets and sidewalks where specified on the
drawings in:
C13.7.7.1 Barriers and Parapets (type of joint indicated) number (No)
C13.7.7.2 Sidewalks (type of joint indicated) number (No)

The unit of measurement shall be the number of each type and size of cover plates installed.
The tendered rate shall include full compensation for the supply and installation of the cover plate and box outs as detailed on the drawings. The
tendered rate shall also include for all stainless steel bolts and fixing anchors’ and incidentals as specified.
C13.7.8 Additional water tests for joints ordered by the Engineer number (No)
The unit of measurement shall be the number of additional water tests for proving the expansion joints, as ordered by the Engineer.
The tendered rate shall include full compensation for providing the pond of water and maintaining its minimum depth of 150mm for the full one
hour period, and clearing away the ponding materials on completion.
C13.7.9 Specialist proprietary expansion joints:
C13.7.9.1 Prime cost sum allowed for purchasing and taking delivery of expansion joints prime cost sum
C13.7.9.2 Percentage on prime cost sum for charges and profit percent (%)
Payment for purchasing and taking delivery of proprietary expansion joints shall be in accordance with the provisions of the general conditions
of contract (see note 2 below).

C13.7.10 Installation of specialist proprietary expansion joints:
C13.7.10.1 (Description of joint measured per metre) metre (m)
C13.7.10.2 (Description of joint measured by number) number (No)

Notes:
(1) The cost of forming the open joint(s) shall not be included in the rates tendered for items C13.7.5 and C13.7.10 as payment for this work
shall be made under item C13.2.6.
(2) Separate payment shall not be made for supplying and/or installing the seal in proprietary expansion joints or the seal between concrete
or synthetic nosings.
(3) Measurement of and payment for concrete sidewalks (including kerbing and copings) shall be made in accordance with Clauses the
measurement and payment items for formwork, steel reinforcement and concrete.

D13.7 JOINTS
CONTENTS
D13.7.1 SCOPE
D13.7.2 GENERAL
D13.7.1 SCOPE
D13.7.2 GENERAL
The Contractor shall within 28 days of entering into the contract with the Employer submit to the Engineer conformance documentation related to
the specifications. All products used in the manufacture and installation of Bridge joints shall be in compliance with the specifications contained
in Section A13.7.
a) Carbon Steel
b) Stainless Steel
c) Elastomeric Glands
d) Asphaltic Plug joint material.
e) All sealants
f) Epoxy Adhesives
g) Epoxy Mortars

The design and installation of proprietary bearings shall require a warranty of 25 years to be supplied by the Contractor. The format of this
warranty shall be as per Form D13.7.2 hereafter. A full set of drawings of the proprietary joints shall be submitted together with certificates of all
tests carried out in accordance with the manufacturers or Agrément requirements. Certification of the installation by a suitably experienced
ECSA Registered Professional Engineer or Technologist is also required together with the warranty.
The following periods are prescribed for bridge deck expansion joints as follows:
Proprietary Joints - 25 years
Asphaltic Plug Type Joint - 15 years
Elastomeric Glands - 15 years.


FORM D13.7.2
WARRANTY FOR DESIGN, MANUFACTURE AND INSTALLATION OF PROPRIETARY BRIDGE
DECKS EXPANSION JOINTS ON (CONTRACT NUMBER AND DESCRIPTION)
DESCRIPTION DETAILS
Bridge Number and

Type of Joint
Name and Address

of Contractor
Name of Contact
Person
Name and Address

of Manufacturer
Name of Contact
Person
Name and Address

of Installer
Name of Contact
Person
Date of Manufacture
Date of Installation
Duration of
Warranty
Start date of
Warranty
End date of
Warranty
The Contractor, Manufacturer and Installer hereby warrant that the above joints will perform satisfactorily in terms of workmanship and durability,
and that the joints have been installed in accordance with the patent holder’s requirements and as set out in the specifications and on the
drawings for each particular joints.
This warranty is for 25* or 15* years from the completion date of the Main Contract for the project. (*Delete whichever is not applicable).
In the event that the performance of the joints is not in accordance with this warranty due to materials or workmanship defects, the Contractor
undertakes to rectify the joints within 90 days of receiving the instruction to do so by the Employer.
The joints shall be completely replaced including, supply and installation including all other costs associated thereto (i.e. Traffic Accommodation,
Closure of the road and bridge as agreed to by the Employer) to the satisfaction of the Engineer.
SIGNED ON BEHALF OF MAIN CONTRACTOR: ________________________________________________________________
on behalf of: _________________________________________________________________________________
Address: _________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Telephone No: _________________________________________________________________________________
SIGNED ON BEHALF OF MANUFACTURER: ___________________________________________________________________
on behalf of: _________________________________________________________________________________

Address: _________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Telephone No: _________________________________________________________________________________
SIGNED ON BEHALF OF INSTALLER: ____________________________________________________________________
on behalf of: _________________________________________________________________________________
Address: _________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Telephone No: _________________________________________________________________________________
WITNESS:
Signature: _________________________________________________________________________________
Name: _________________________________________________________________________________
Address: _________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Telephone No: _________________________________________________________________________________

13.8 ANCILLARY STRUCTURAL ELEMENTS
CONTENTS
A13.8.1. SCOPE
A13.8.2 DEFINITIONS
A13.8.3 GENERAL
A13.8.5 MATERIALS
A13.8.8 WORKMANSHIP

A13.8 ANCILLARY STRUCTURAL ELEMENTS

A13.8.1 SCOPE
a) The construction of barriers, parapets, railings and sidewalks on structures.
b) The construction and installation of drainage works such as weep holes, drainage pipes and gulley’s, no-fines concrete blocks, filter lining
and concrete channels; and.
c) The installation of bolt groups for electrification brackets.
d) The installation of service ducts
A13.8.2 DEFINITIONS
Concrete Barriers - a barrier is a concrete element which separates lanes of traffic (or pedestrians) in the same or opposing directions.
Parapets - a parapet is an element constructed on sides of bridges and other structures to prevent traffic from falling off where there is a vertical
drop.
Railings - railings manufactured from various materials are constructed along footwalks to prevent pedestrians from falling off where there is a
drop.
Transition Blocks - transition blocks are concrete members constructed between elements of different cross sections such as barriers, end
blocks, parapets, kerbs and channels etc.
Synthetic Fibre - is a geotextile fabric with a specific tensile strength and flow rate through the fabric to allow water to permeate through it but to
retain fine materials.
Copings - copings are concrete elements which are constructed on retaining walls, decks and footwalks as a finish to these members. Railings
in concrete or steel are cast into copings.
A13.8.3 GENERAL
The ancillary items for structures covered in this section consist of concrete elements constructed on site or elements which are precast
concrete, steel or other materials used for the construction or manufacture of the elements which are specified in this Chapter. All cast in situ
elements and manufactured items shall be constructed or manufactured as indicated on the drawings from materials as specified in of these
specifications or in other Chapter the relevant SANS, BS and EN specifications.

Where alternative designs or materials are proposed by the Contractor to be used in certain elements of the structure these designs or the
proposed materials shall be submitted to the Engineer for approval 28 days before the manufacture or supply of such elements.
A13.8.5 MATERIALS
A13.8.5.1 Barriers, parapets, railings and sidewalks for structures.
a) Concrete
All concrete work shall be carried out in accordance with the requirements of Sections A13.2, A13.3 and A13.4.
b) Structural steel
Structural steel work shall comply with the provisions of Section A13.7.
c) Mortar
Mortar shall comply with the requirements of Clause A13.6.5.1g).
d) Painting
Painting shall comply with the requirement of Section A13.12.

The Contractor shall before construction commences, provide comprehensive details of all plant and equipment, which shall be appropriate for
the intended use.

A13.8.7.1 Barriers, parapets, railings and sidewalks
a) Concrete barriers and parapets
Vehicle containment Concrete barriers and parapets on Bridges and on top of retaining walls shall always be cast in situ as shown on the
drawings.
Concrete barriers and parapets on bridges shall be constructed after the removal of the false work and the completion of the prestressing, but
not before the bridge deck has been accurately measured so as to determine the final lines and levels. Service ducts in barriers, parapets and
end blocks shall be fixed and cast in accordance with the requirements of Clause A13.4.7.11k)(i) and the details shown on the drawings. Precast
alternatives for parapets shall not be permitted.
“Precast Barrier in medians and adjacent to retaining walls in cutting may be permitted if indicated on the drawings. Precast Concrete Median
Barriers which are integrated into an in-situ reinforced concrete framework are permitted where the difference in height between the top of the
precast units on each side are less than 125 mm. For higher differences in height a precast barrier may be permitted on the lower and higher
side when the higher barrier is constructed into a reinforced concrete retaining wall. When retaining walls are constructed in the median or
adjacent to fills the In-situ reinforced concrete Barriers and Parapets shall always be constructed on the top of retaining walls or be supported on
their own cast reinforced concrete foundations.”
The pipes and fittings to be used for the construction of the ducting shall be rigid PVC pipes and fittings with flexible rubber joints which comply
with the requirements of SANS 967. Duct ends shall be provided with end caps to prevent dirt, concrete, etc., from entering the ducts. Two
strands of 2,5 mm diameter galvanized steel wire shall be threaded through each duct. The strands shall extend 2,0 m beyond each end and be
wedged firmly into position with the wooden stoppers. Inspection eyes for the ducts shall be constructed in accordance with the details shown
on the drawings.
No separate payment will be made for service ducts in barriers, parapets and end blocks and the rates tendered for the barriers, parapets and
end blocks shall include full compensation for the provision and installation of service ducts complete with stoppers, draw wires and Inspections
eyes.
b) Steel railings
All steelwork shall be manufactured in accordance with the requirements of Section A13.9.
A mortar bed, not less than 10 mm in thickness, shall be provided below all steel base plates over the full dimensions of the plate. The sides of
the beds shall be neatly chamfered at 45°. All open spaces between the bolt and the sides of the holes in the base plate shall be grout filled.
Steelwork which is to be cast or grouted into concrete shall be completely painted to a depth of 75 mm in the concrete or grout, and shall be
cleaned of all loose rust, mill scale, oil or other material which may impair the bond between the concrete and steel.
All steelwork shall be painted in the shop and on site in accordance with the provisions Section A13.11. Surfaces which will be inaccessible
after erection of the units shall be painted before erection commences. If called for on the drawings or in the schedule of quantities, steelwork
shall be galvanised and painted. Galvanising shall be done after fabrication, in accordance with SANS 32 and or SANS 121.
c) Concrete railings
All concrete work to manufacture or construct concrete railings shall be carried out in accordance with Sections A13.2, A13.3 and A13.4.
The vertical posts and horizontal railing shall be cast on site or manufactured as detailed on the drawings and cast into the kerbs or footwalks of
the structure. Special attention shall be given to the top railing being erected to the line and level of the footwalks and railings as indicated on the
drawings. All the posts supporting the railings shall be vertical.
d) Numbers for structures
(i) Number plates
Number plates shall be fixed in the positions and according to the method of fixing shown on the drawings. Number plates shall be
cast from nonmetallic materials. The minimum overall thickness shall be 11 mm and a background plate with a minimum thickness
of 8,0 mm. The letter thickness shall not be less than 3,0 mm. Laminated PVC or other laminated materials shall not be permitted.
(ii) Painted numbers
The surface onto which the numbers are to be painted shall be prepared in accordance with the requirements of Section A13.12.
The background shall be of at least two coats of the prescribed paint. The letters and figures shall be in accordance with the
details given on the drawings and shall be written at the prescribed positions with a template.
(iii) Numbers shaped in concrete
Bridge numbers shall be placed and shaped in accordance with the requirements shown on the drawings. The minimum concrete
cover over the steel reinforcement behind the numbers shall not be less than the prescribed cover for the structural member in
question.
e) Concrete sidewalks
After completion of the prestressing and the removal of the formwork, the sidewalks and kerbing shall be constructed, but not before the bridge
deck has been accurately surveyed to establish final lines and levels after the falsework has been removed.
The previously cast bridge deck area shall be prepared as specified in Section A13.4 to receive the sidewalk concrete.
Forms shall be accurately set to the final lines and levels and shall be firmly held in position during the placing of the concrete. Stops at the
ends of sections shall be accurately placed to ensure that joints between adjacent sections will be truly perpendicular to the surface of the
concrete and at right angles to the edge of the road or to the skew angle of the deck at the expansion joint. All finishing chamfers shall be firmly
installed on formwork within final tolerance for completed concrete.
After removal of the forms, the exposed surfaces of the kerbs and copings shall be rubbed and finished in accordance with the requirements of
Clauses A13.2.7.4c) and (iii) and A13.2.7.2b). All edges shall be rounded to a radius of 20 mm unless otherwise shown on the drawings
f) Service Ducts in Sidewalks and Structures
When required, the Contractor shall construct service ducts for the easy installation and maintenance of existing, new and future services.
Service ducts shall be normal duty uPVC pipes in accordance with SANS 791. All pipes shall be joined with water tight couplings made of the
same material as the pipe. The couplings shall be adequate at expansions joints to provide for deck movements as detailed on the drawings.
All ducts shall be suitably fixed at 500 mm centres to prevent horizontal and vertical movement.
Duct ends shall be provided with suitable end caps to prevent material from entering the ducts.
Two stands 2,5 mm diameter galvanised steel wire shall be threaded through each duct and shall extend 3,0 m beyond each end.
g) Concrete surface finish requirements
All formed concrete surfaces shall have a class F3 surface finish as specified in Clause A13.2.7.2b) and all unformed concrete surfaces shall
have a class U3 surface finish in accordance with Clause A13.2.7.2c).
h) Transition blocks
Transition blocks shall be constructed in accordance with the details shown on the drawings.
A13.8.7.2 Drainage for structures

a) Weep holes, drainage pipes and channels
Weep holes shall not be placed within 40 mm of any reinforcement and shall be carefully cleaned and kept clean.
Drainage pipes shall be of the material prescribed on the drawings, and the interior surface shall, on completion, be smooth and clean.
Perforated drainage pipes for drainage behind retaining walls and abutments shall comply with the requirements of Clause A3.1.5.2a) of Chapter
3.
Cast in situ concrete channels shall be provided next to the kerbing if shown on the drawings and according to the details provided. Concrete
work shall be carried out in accordance with the provisions of Section A13.4 and channels shall be given a class U2 surface finish as specified in
Clause A13.2.7.2c). The channels shall be bonded to the bridge deck concrete in accordance with the provisions of Clause A13.4.7.11g).
b) No-fines concrete blocks
Blocks shall be of the class of prescribed no-fines concrete and to the required dimensions and shall be placed in advance of backfilling.
No-fines concrete shall comply with the requirements of Clause A13.4.7.11f).
c) Synthetic filter fabric
Synthetic-fibre filter fabric shall be of the type and grade shown on the drawings or specified in the Contract Documentation. Filter fabric shall
be placed as shown on the drawings and shall be protected against sunlight and mechanical damage during storage and installation.
The fabric shall comply with the requirements of geotextiles as per Section A12.11 of Chapter 12.

d) Crushed stone in drainage strips behind walls
The crushed stone used in drainage strips shall comply with the requirements for 19 mm nominal size stone as specified in table 9 of SANS
1083. The crushed stone shall be wrapped in synthetic-fibre geotextile and placed in accordance with the details shown on the drawings or as
A13.8.7.3 Bolt groups for electrification brackets

If specified the Contractor shall supply and install bolt groups in bridge decks for the electrification brackets of railway owners. The bolt groups
shall consist of stainless-steel sockets complete with stainless-steel bolts and mild-steel plates. The sockets, bolts and plates shall be
manufactured in accordance with the details shown on the drawings. The Contractor shall install the sockets in bridge decks in the positions
and in the manner shown on the drawings.
On completion of the deck, the Contractor shall ensure that the threads of the bolts and sockets are clean and that the bolts can be secured in
the sockets. The brackets shall be as specified by the applicable Railway Authorities.
A13.8.8 WORKMANSHIP
The tolerances given below shall be the maximum permissible deviations from the specified dimensions, levels, alignment, positions, etc.,
a) Chamfers
Fillets used for forming chamfers shall be within a tolerance of 1,0 mm in cross-sectional dimensions, and the actual chamfer on the concrete
shall not vary by more than 3,0 mm from the specified dimensions.
b) Barriers, parapets, railings, footwalks and kerbs.
The members shall be constructed within a tolerance ± 5,0 mm for all dimensions. The vertical and horizontal alignment shall not deviate from
the true alignment by more than 10 mm in any location, nor shall the alignment deviate by more than 5,0 mm from the true alignment over any
length of 5,0 m.
c) Service ducts
Service ducts shall be placed horizontally and vertically to a tolerance of 10 mm.
d) Brackets
Brackets shall be fixed to a horizontal tolerance of 20 mm.
e) Copings
Coping shall be constructed to an alignment tolerance of ± 10 mm and for level tolerance of ± 5,0 mm.

B13.8 ANCILLARY STRUCTURAL ELEMENTS
CONTENTS
B13.8.1 SCOPE
B13.8.2 DEFINITIONS
B13.8.3 GENERAL
B13.8.5 MATERIALS
B13.8.8 WORKMANSHIP
B13.8.1 SCOPE
a) The construction of barriers, parapets, railings and sidewalks on structures.
b) The construction and installation of drainage works such as weep holes, drainage pipes and gulley’s, no-fines concrete blocks, filter lining
and concrete channels; and.
c) The installation of bolt groups for electrification brackets.
d) The installation of service ducts
Part A is suitable for labour enhanced work.
B13.8.2 DEFINITIONS
The provisions contained in Part A shall apply.
B13.8.3 GENERAL

B13.8.5 MATERIALS


B13.8.8 WORKMANSHIP

C13.8 ANCILLARY STRUCTURAL ELEMENTS
(i) Preamble
None.
pay items.
End Blocks C13.8.2 Chapter 4 - All applicable items
Cast in situ no-fines concrete C13.8.8 C13.4.7.1 - All applicable items
C13.8.1 Concrete barriers and parapets (refer to drawings)
C13.8.1.1 Barriers metre (m)
C13.8.1.2 Parapets metre (m)

The unit of measurement for concrete parapets shall be the metre of concrete parapet complete in accordance with the drawings. Concrete
parapets shall include all work above the top level of the sidewalks or, where not placed on a sidewalk, above the top of the bridge deck
concrete, wingwalls or retaining walls and shall also include any kerbing and coping forming an integral part of the concrete parapet.
The tendered rate for concrete parapets shall include full compensation for all concrete, formwork, service ducts, drawing wires and accessories.
The rates will exclude only the cost of reinforcing steel as this will be measured and paid for under another pay item.
The tendered rate shall also include for sealing of joints between barriers and parapet units as shown on the drawings.

C13.8.2 End blocks (length indicated) number (No)

The unit of measurement of bridge end blocks shall be the number of end blocks constructed complete including all built in items in accordance
with the drawings.
The tendered rate shall include full compensation for all materials, labour, plant, and other incidentals required for constructing the end blocks
complete as specified excluding only reinforcing steel. The rate for end blocks shall also include all the attachment brackets, bolts and other
fixtures required to attach the steel traffic barriers to the end block. All barrier attachment brackets off the end block shall be measured under the
appropriate pay items in Chapter 4.
C13.8.3 Concrete transition blocks (length indicated) number (No)

The unit of measurement shall be the number of each size of concrete transition block constructed complete in accordance with the details
The tendered rate shall include full compensation for all labour, constructional plant, materials and all incidentals required for constructing the
transition blocks.
C13.8.4 Concrete pedestrian railings metre (m)

The unit of measurement shall be the metre of railing complete in accordance with the drawings.
The tendered rate shall include full compensation for all labour, plant and materials (including reinforcing steel and prestressing requirements)
for the manufacture and erection of the precast concrete railings. The concrete railing shall include for fixing the concrete railing into the
sidewalk.
C13.8.5 Steel railings (type described) metre (m)

The unit of measurement for steel railings shall be the metre of railing complete in accordance with the drawings.
The tendered rate for steel railings shall include full compensation for all steelwork and corrosion protection, including fastenings, anchor bolts,
mortar bedding, etc, as may be required, and for erecting the steel railings, complete as specified.
C13.8.6 Service ducts in structures
C13.8.6.1 Type and size (diameter) metre (m)
C13.8.6.2 Joint in ducts at bridge deck expansion joints number (No)

The unit of measurement shall be the metre of service duct installed.
The tendered rate shall include full compensation for procuring and installing service ducts, including, end caps, draw wires and complete
installation.
C13.8.7 Numbers for structures: (refer to drawings)
C13.8.7.1 Number plates number (No)
C13.8.7.2 Painted numbers number (No)
C13.8.7.3 Numbers formed in concrete number (No)
C13.8.7.4 Numbers on concrete pedestals number (No)

The unit of measurement shall be either the number of bridge number plates provided and installed, or the number of complete numbers painted
on the structures, or the number of complete numbers formed in concrete. A bridge number may consist of a combination of letters and digits,
e.g. B1533.
The tendered rates shall include full compensation for providing and installing either the number plates, or preparing the surface and painting
the numbers, or forming the numbers in concrete, and for all material, labour and equipment required in this connection.

C13.8.8 Cast in situ no-fines concrete (class of concrete indicated) cubic metre
The provisions of Clause A13.4.7.12f) and item C13.4.7.1 shall apply mutatis mutandis.
C13.8.9 Precast no-fines concrete units (class of concrete and description of unit) number (No)
The unit of measurement shall be the number of complete units of each size and type in position in the works.
The tendered rate for each precast concrete unit shall include full compensation for providing all the materials, labour, plant and formwork
required for manufacturing the unit complete as shown on the drawings and for transporting and placing the unit in position.
C13.8.10 Drainage pipes and weep holes:
C13.8.10.1 Drainage pipes:
(a) (Type and size indicated) metre (m)
(b) (Type and size indicated) number (No)
C13.8.10.2 Weep holes:
(a) (Type and size indicated) metre (m)
(b) (Type and size indicated) number (No)

The unit of measurement shall be either the metre of pipe/weep hole or the number of pipes/weep holes of each type and size of pipe/weep hole
completed as specified on the drawings.
The tendered rates shall include full compensation for supplying all the materials, manufacturing and installing the pipes and making weep
holes.
C13.8.11 Drainage gulley’s (description of each type given) number (No)

The unit of measurement shall be the number of drainage gulleys of each type installed.
The tendered rate shall include full compensation for providing all the material and manufacturing and installing the drainage inlets.
C13.8.12 Synthetic-fibre filter fabric (type indicated and description) square metre (m2)
The unit of measurement shall be the square metre of filter fabric installed as specified, including the specified overlap.
The tendered rate shall include full compensation for supplying, cutting and installing the filter fabric, and for waste material.
C13.8.13 Concrete channels adjoining structural works (size indicated) metre (m)
The unit of measurement shall be the metre of completed concrete channeling of each size constructed.
The tendered rate shall include full compensation for providing all the material, all labour, equipment and expenses required for completing the
work.
C13.8.14 Crushed stone in drainage strips (stone size indicated) cubic metre (m3)
The unit of measurement shall be the cubic metre of crushed stone placed in position as specified, in accordance with the details shown on the
drawings or instructed by the Engineer.
The tendered rate shall include full compensation for procuring, furnishing and placing the crushed stone, and for wrapping it in synthetic-fibre
geotextile as specified.
The geotextile will be measured for payment under item C13.8.12.

C13.8.15 Drainage strips (type, size and grade indicated) metre (m)
The unit of measurement shall be the linear metre of drainage strips placed at the structure / earth interfaces as shown on the drawing.
The tendered rate shall include full compensation for all material, labour, and equipment to supply and install the strips as shown.
C13.8.16 Perforated drainage pipes:

C13.8.16.1 Size (diameter) and type of pipe wrapped in synthetic – filter fabric as specified (describe metre (m)
type, grade etc.)
The unit of measurement shall be the linear metre of perforated drainage pipes placed behind the earth faces as shown on the drawing.
The tendered rate shall include full compensation for all material, labour, and equipment to supply and install the perforated pipes as shown
including the 300 mm wide by 50 mm thick mortar bed under the core.
C13.8.17 Supplying and installing bolt groups complete with electrification brackets:
C13.8.17.1 Single-bolt groups number (No)
C13.8.17.2 Double-bolt groups number (No)

The unit of measurement shall be the number of each type of bolt group and brackets supplied and installed complete in position in accordance
with the details shown on the drawings.
The tendered rates shall include full compensation for procuring and furnishing all materials, manufacturing, transporting and storing, and all
labour, constructional plant and materials required for installing the bolt groups as specified.

D13.8 ANCILLARY STRUCTURAL ELEMENTS
CONTENTS
D13.8.1 SCOPE
D13.8.2 GENERAL
D13.8.1 SCOPE
D13.8.2 GENERAL
The Contractor shall within 28 days before manufacture submit to the Engineer conformance documentation related to the specifications. All
products used in the manufacture and installation of Ancillary Structural Elements shall be in compliance with the specifications contained in
Section A13.8.
a) Concrete Pedestrian Railings.
b) Steel Pedestrian Railings.
c) PVC or Polyethylene Drainage Pipes.
d) Drainage Gullies
e) Synthetic-fibre filter fabric
f) Perforated PVC or Polyethylene pipes.
g) Bridge Number Plates.

No warranties are required for Ancillary Structural Elements.


13.9 STRUCTURAL STEELWORK FOR MINOR STRUCTURES
CONTENTS
A13.9.1 SCOPE
A13.9.2 DEFINITIONS
A13.9.3 GENERAL
A13.9.5 MATERIALS
A13.9.8 WORKMANSHIP

A13.9 STRUCTURAL STEELWORK FOR MINOR STRUCTURES

A13.9.1 SCOPE
This Section covers the manufacture, transport and erection of structural steelwork for minor structures, e.g. overhead road-sign structures and
light mast anchor bolts. It does not apply to major steel structures such as steel and composite steel bridges, which is covered in Section
A13.11.
A13.9.2 DEFINITIONS
A13.9.3 GENERAL

A13.9.4.1 Codes of practice
The design, where undertaken by the Contractor, of all work shall comply with the requirements of SANS 10162.
A13.9.4.2 Shop details

Where shop details have not been furnished on the drawings, the Contractor shall prepare his own shop details in accordance with the
provisions of Clause A1.2.4 of Chapter 1. Shop details shall be approved and signed by the Engineer prior to the fabrication of any items.
A13.9.5 MATERIALS
A13.9.5.1 Structural steel
Structural steel shall comply with the following requirements:
Mild steel: SANS 50025 (EN 10025) grade S275JR
High-yield stress steel: SANS 50025 (EN 10025) grade S355JR
The dimensions and properties of rolled steel sections shall comply with the prescriptions given in the structural steel tables issued by the SA
Institute of Steel Construction.
A13.9.5.2 Steel tubes

Steel tubes shall comply with the requirements of SANS 657, part 1.
A13.9.5.3 Bolts, nuts and washers
Ordinary bolts and nuts shall be bolts and nuts used for transferring forces by tensile stress, compressive stress and shear stress without any
friction-grip action being considered. Ordinary bolts and nuts shall comply with SANS 1700-7, SANS 1700-14 or SANS 1143.
Washers for ordinary bolts and nuts shall comply with the requirements of SANS 1700-16.
Friction-grip fasteners:
High-strength friction-grip bolts, nuts and washers shall comply with the requirements of SANS 1700-7 and SANS 1700-14.
Other friction-grip fasteners equal to the above shall only be used if approved by the Engineer.
A13.9.5.4 Rivets
Mild-steel rivets shall comply with the requirements of SANS 1700-18. High-tensile rivets shall be so manufactured that they can be driven and
their heads formed satisfactorily without the physical properties of the steel being impaired.
A13.9.5.5 Welding consumable

Welding electrodes shall comply with the requirements of SANS 455.
The quality, handling and storage of all consumables shall be so as to achieve the desirable properties of the weld metal.
The welding consumables used shall be appropriate to produce weld metal which will yield all the weld-metal test specimens as specified in BS
EN ISO 4136, BS EN ISO 5173, BS EN ISO 5178, BS EN ISO 9015, BS EN ISO 9016, BS EN ISO 9017, BS EN ISO 9018 and BS EN ISO
17639, having both minimum yield and minimum tensile strengths not less than those of the parent metal.
A13.9.5.6 Test certificates

The Contractor shall submit test certificates, as required by the Engineer, of the structural steel and anchor bolts that will be used.

A13.9.7.1 Fabrication and assembly
a) General
All structural steel both before and after fabrication shall be within the tolerances specified in Clause A13.9.8.2 and shall be flat, straight (unless
required to be formed to another shape) and free from twists.
b) Marking the steel
At all stages of fabrication, all structural steel other than grade S275JR steel shall be clearly marked by grade by means of a suitable marking
system.
c) Cutting
Steel shall be cut by sawing, shearing with shears, cropping, or flame-cutting.
Edges shall be free from any defects or distortions and all burrs, notches and similar defects shall be removed.
d) Holes for fasteners
Holes for fasteners shall not be formed by flame cutting. Holes in light members not thicker than 12 mm or the diameter of the hole, whichever is
the smaller, may be punched.
Holes for fasteners of up to 25 mm in diameter shall not be more than 2,0 mm larger than the diameter of the fastener and holes for larger
fasteners not more than 3,0 mm larger than the diameter of the fastener.
Holes for friction-grip fasteners shall be in accordance with SANS 10094.
All burrs shall be removed from holes before assembly.
e) Joints in compression
The abutting surfaces of joints dependent on contact for the transmission of load shall be accurately prepared so that the full area intended for
bearing will be in contact as specified in Clause A13.9.8.2.
f) Hollow sections
Unless protection against corrosion is provided by other means, the interior of any hollow section shall be sealed to prevent the ingress of
moisture. Where a sealed hollow member is holed for a fastener or pin, precautionary measures shall be taken to prevent the ingress of water
to the interior of the member. Vent holes for galvanising shall be sealed after galvanising has been completed.

g) Alignment of holes
All matching holes for fasteners or pins shall be accurately aligned so that the fasteners can be inserted freely through the assembled members
in a direction at right angles to the faces in contact. Drifting for aligning the holes shall not distort the metal or enlarge the holes.
h) Welding
Welding shall be done in accordance with the requirements of BS EN 1011.
The welding techniques shall be such as to avoid undue distortion and to minimise shrinking stresses.
All slag shall be removed.
Where required for certain welding:
(i) the manufacturer shall hold a valid welding-procedures certificate in accordance with SANS 15607 for grade B welding joints, and the
welding shall be done by a welder qualified in accordance with SANS 9606; or
(ii) the welder shall hold a valid certificate of competency in accordance with SANS 9606 for the specified type of welding.
All structural welds shall be full-strength joints.
i) Bolting
The jointed parts shall be firmly drawn together. Where necessary, tapering washers shall be used for each bolt head and nut to transfer the
compressive stress over its full surface. Where bolt holes have greater than normal clearance, washers shall be placed under the bolt heads
and nuts.
The length of each bolt shall be such that, after tightening, at least one full thread projects through the nut on the outside and at least one full
thread (in addition to the thread run-out) remains clear between the nut and the bolt head.
j) Friction-grip and anchor bolt fastening
The use of friction-grip bolts shall be in accordance with SANS 10094. Where use is made of equivalent types of friction-grip fasteners, they
shall comply with the requirements of SANS 10094 for equivalent fasteners and shall be installed in accordance with the appropriate
Friction-grip bolts and anchor bolts shall be tightened by “method of turn” and not by torque wrench. Due care shall be taken to avoid over-
tightening leading to fatigue failure.
k) Riveting
Wherever possible, riveting shall be done with pneumatic equipment.
Riveted units shall have all parts firmly drawn together and aligned before riveting. Every rivet shall, when driven, completely fill the hole and
shall have a well-formed head or, if countersunk, fill the countersink completely.
All loose, eccentric-headed, badly formed, burnt or otherwise defective rivets shall be cut out and replaced.
l) Trimming
All fabricated steel work shall be neatly trimmed so as not to show any sharp edges. Acute angles shall be rounded off to a radius of at least 1
mm.
m) Corrosion prevention
(i) Painting
Before removal from the place of manufacture the steelwork shall be painted as specified in Section A13.10.
Where the finishing coats are to be applied on the site, the shop painting shall include the application of an undercoat as specified
in Section A13.10.
Galvanised steel shall not be painted unless painting is specifically called for in the specifications or on the drawings.
(ii) Sprayed metal coatings
Where the sprayed metal coating of steel surfaces is called for, it shall be done in accordance with the requirements of SANS
2063. The type of metal used shall be as specified, and, unless otherwise specified, the metal coating shall comply with the
requirements of type Al 150 or type Zn 150.
(iii) Galvanising
Where the galvanising of structural steelwork is required, the members shall be hot-dip galvanised. Structural steel members shall
be given an 85 micrometre coating or such other thickness as may be specified in accordance with SANS 121, and sheet steel
and strip shall be given a class M coating in accordance with SANS 4998.
All steel to be galvanised shall be compatible with the galvanising process. Due care shall be taken to avoid hydrogen
embrittlement.
All nuts, bolts, screws and threaded articles shall be hot-dipped galvanised in accordance with the appropriate requirements of
SANS 121 for type C1 or type C2 articles. Electroplating shall not be used.
Cut ends and small damaged areas shall be repaired by the application of a zinc-rich paint or by zinc spraying. Large damaged
areas and site welds shall be repaired by zinc spraying.

A13.9.7.2 Erection
a) General
Where specified, details of the method of erection shall be submitted to the Engineer for approval. All structural steel shall be stored,
transported, handled and erected so as not to subject it to undue stress or damage.
Erection over traffic is not permitted, and a temporary deviation for traffic shall be provided.
Provision for traffic accommodation will be paid for in accordance with the appropriate items under Section C1.5 of Chapter 1.
b) Safety during erection
During the erection of a structure, the steelwork shall be bolted, braced or otherwise secured so as to make adequate provision for all erection
loads.
c) Alignment
Each part of a structure shall be aligned as soon as possible after erection. Members shall not be permanently connected until sufficiently large
members of the structure have been aligned, plumbed, levelled, and temporarily secured to prevent their displacement during the erection or
alignment of the remainder of the structure.
d) Corrections
Drift pins, jacking equipment and the like shall not be used for bringing improperly fabricated members into place. A moderate degree of cutting
and reaming may be done to correct minor misfits if, in the opinion of the Engineer, this will not be detrimental to the appearance or strength of
the structure. The burning of holes will not be permitted without written approval.
e) Repairs to painting and site painting
Repairs to painting and site painting shall be effected in accordance with the provisions of Clause A13.10.7.5.
f) Grouting
The grout shall be poured under and around the base plates of columns after the steelwork has been finally checked for alignment and height
and after the approval of the Engineer has been obtained to proceed with the grouting. The column base plates shall be supported by the top
and bottom nuts and by steel wedges. The area under the steel shall be thoroughly cleaned and shall be dust and oil-free, and the concrete
shall be thoroughly rinsed with water to leave the surface clean and moist.
The grout shall be an approved non-shrinking, pourable, cementitious grout. The grout shall be prepared and applied strictly in accordance with
the manufacturer's recommendations and the Engineer's directives.
Leak-proof formwork shall be used for the pourable grout, and all corners shall be chamfered. The surface finish shall be class F2 and class U2
as applicable.
A13.9.8 WORKMANSHIP
A13.9.8.1 Testing
a) Testing by the Engineer
The Engineer may nominate a testing authority to inspect the works and to conduct such tests as he may deem to be necessary to test
compliance with the specifications. Where required, test samples of welds shall be prepared by the Contractor, free of charge.
Payment for these tests shall be made under Section C20.1 of Chapter 20.
b) Process control
Welds shall be regularly inspected and tested by the Contractor in terms of his obligations in regard to process control, as described in Clause
A1.2.8.1 of Chapter 1. This shall include visual inspection of welds to ensure that no undercutting, uneven lengths, porosity, or evidence of
cracking occurs and that full fusion of the metals has been achieved. In doubtful areas, cores containing weld metal and adjacent parent
material shall, if so required by the Engineer, be cut out, polished and examined and the hole repaired.
At least 30 % of the welds shall be examined by ultrasonic or radiographic means. If more than 5 % of the examined welds show unsatisfactory
results, additional examinations covering all welds shall be performed. Certificates of the examination confirming that the steel plates and welds
comply with the requirements of SANS 15614 shall be submitted to the Engineer.
The cost of testing shall be deemed to be included in the rate tendered for item C13.9.1 Structural steel.
The tolerances given below shall be the maximum permissible deviations from the specified dimensions, levels, alignment, positions, etc., shown
on the drawings of the structures or structural members.
a) General
The fabrication and assembly tolerances on all dimensions for structural steel shall be ± 2,0 mm. Holes for connections shall be drilled/punched
and aligned as specified in Clauses A13.9.7.1 d) and g) respectively.
b) Cross-section
The tolerances on cross-sectional dimensions of rolled sections shall be as specified in the Structural Steel Tables, published by the SA Institute
of Steel Construction.

c) Straightness
A structural member before erection shall not deviate from straightness or the specified shape by more than the following:
For compression members and beams, one-thousandth of the length between points which are laterally restrained.
For other members, one five hundredth of the overall length, but not exceeding 25 mm.
d) Length
The length of a member shall not deviate from its prescribed length by more than the following:
For compression members faced at both ends for bearing, ± 1,0 mm
For other members, + 0, -4,0 mm.
For such members as trusses and lattice girders, the above tolerances shall apply to the members as a whole.
The lengths of component parts shall be such that the structural member can be properly assembled with the required accuracy.
e) Bearing surfaces
Where two steel surfaces are required to be in contact for transferring compressive forces, the maximum clearance between the bearing
surfaces shall not exceed 1,0 mm when the members in contact are aligned.
f) Accuracy of erection
Steelwork shall not be out of plumb over any vertical distance by more than 5,0 mm or one thousandth of the distance, whichever is the greater.

B13.9 STRUCTURAL STEELWORK FOR MINOR STRUCTURES
CONTENTS
B13.9.1 SCOPE
B13.9.2 DEFINITIONS
B13.9.3 GENERAL
B13.9.5 MATERIALS
B13.9.8 WORKMANSHIP
B13.9.1 SCOPE
This Section covers the manufacture, transport and erection of structural steelwork for minor structures, e.g. overhead road-sign structures. It
does not apply to major steel structures such as steel and composite steel bridges, which is covered in Section A13.12. Part A is suitable for
labour enhanced work at varying skill levels.
B13.9.2 DEFINITIONS
B13.9.3 GENERAL

B13.9.5 MATERIALS


B13.9.8 WORKMANSHIP

C13.9 STRUCTURAL STEELWORK FOR MINOR STRUCTURES
(i) Preamble
None.
products.
Corrosion Protection C13.9.3.1 and C13.9.3.2 C13.10.1 - All applicable items
C13.9.1 Structural steel:
C13.9.1.1 (Structure/article described) ton (t)
C13.9.1.2 (Structure/article described) metre (m)
C13.9.1.3 (Structure/article described) number (No)

The unit of measurement shall be either the ton or the metre of erected permanent steel structures or articles, or the number of erected
permanent steel structures or articles. Where the unit of measurement is the ton, the mass of the steel waste caused by punching, drilling,
sheared edges, milling or planing, or metal cut-outs shall not be deducted, and the mass of rivets, bolts, nuts, washers, welding fillets or
temporary bracing shall not be added. In computing the mass of steel, the nominal mass per unit of length or area will be used and tolerances
and other permissible deviations will be ignored.
The tendered rates shall include full compensation for preparing shop details not provided on the drawings, the supply of all the required
materials, fabrication, process control, loading, transporting to the site, off-loading, and erecting. It shall also include full compensation for all
welding, nuts, bolts, washers, rivets, cutting, waste, and any temporary bracing necessary for transporting and erecting.

The tendered rate shall also include full compensation for supplying and pouring the specified grout under and around the base plates of steel
columns, for procuring and supplying all the necessary labour, constructional plant, tools and materials, as well as waste, formwork for the grout,
and finishing to obtain the required surface finish for the grout under and around base plates of steel columns.
C13.9.2 Anchor bolts:
C13.9.2.1 (Description of each assembly, and grade/type of steel, diameter and length indicated) kilogram (kg)
C13.9.2.2 (Description of each assembly, and grade/type of steel, diameter and length indicated) number (No)
The unit of measurement shall be either the kilogram of installed anchor-bolt assemblies or the number of installed anchor-bolt assemblies.
The tendered rates shall include full compensation for the materials, fabrication, handling, transporting and installing the anchor-bolt assemblies,
including corrosion protection.
C13.9.3 Corrosion protection:
C13.9.3.1 Sprayed-on metal:
(a) (Type of metal and thickness or type symbol of coating indicated) ton (t)
(b) (Type of metal and thickness or type symbol of coating indicated) metre (m)
(c) (Type of metal and thickness or type symbol of coating indicated) number (No)
C13.9.3.2 Galvanising
(a) (Thickness or type symbol of zinc coat indicated) ton (t)
(b) (Thickness or type symbol of zinc coat indicated) metre (m)
(c) (Thickness or type symbol of zinc coat indicated) number (No)

The unit of measurement shall be either a ton or a metre of steel structures or articles protected against corrosion, or the number of steel
structures or articles protected against corrosion. The quantities are calculated as specified in item C13.9.1.
The tendered rates shall be extra over the rates for item C13.9.1 and shall include full compensation for applying the specified corrosion
protection, including surface preparation, materials, labour, tools, equipment and all incidentals required.
Note:
Payment for painting shall be made under item C13.10.1.

D13.9 STRUCTURAL STEELWORK FOR MINOR STRUCTURES
CONTENTS
D13.9.1 SCOPE
D13.9.2 GENERAL
D13.9.1 SCOPE
D13.9.2 GENERAL
a) Structural steel: each type and batch;
b) Other structural steel materials including bolts, nuts, washers, welding material, etc.;
c) Welding procedures; and
d) Certification of welders.



13.10 PAINTING OF MINOR STRUCTURES
CONTENTS
A13.10.1 SCOPE
A13.10.3 GENERAL
A13.10.5 MATERIALS

A13.10 PAINTING OF MINOR STRUCTURES

A13.10.1 SCOPE
This section covers the painting of structural steel to minor structures, guard rails, overhead road sign supports and other minor structures.
Painting of steel and composite steel bridges is covered in Section A13.12.
It excludes the corrosion protection of steel work exposed to aggressive or severe conditions.
A13.10.3 GENERAL
A13.10.5 MATERIALS
Paints shall comply with the requirements of the following specifications:
A13.10.5.1 Primers
Wash primer (metal etch primer).......................................................................................................................................... SANS 723
Calcium-plumbate primer..................................................................................................................................................... SANS 912
Two-pack zinc-rich epoxy primer ......................................................................................................................................... SANS 926
A13.10.5.2 Undercoats
Undercoat ............................................................................................................................................................ SANS 681 (type II)
A13.10.5.3 Finishing coats

Decorative enamel for interior and exterior use ................................................................................................................... SANS 630
High-gloss paint ...................................................................................................................................................... SANS 684 (type A)
Micaceous iron-ore-pigmented paint .................................................................................................................................... SANS 684
Baking enamels ................................................................................................................................................................... SABS 783

Emulsion paint for exterior use (polyacrylic) ....................................................................................................................... SANS 1586
Chloro-rubber paint .........................................................................................................................................Contract Documentation
Bituminous aluminium paint ................................................................................................................................................ SANS 802
A13.10.5.4 Other
Epoxy-tar paints ...................................................................................................................................................... SANS 801 (type I)
Bonding liquid for concrete surfaces ...................................................................................................................................... CKS 564
Powder coating .................................................................................................................................................................. SANS 1274
Bituminous-emulsion paint shall consist of a stable bituminous emulsion with a minimum of 45 % of bitumen and about 5 % of approved fibre.

A13.10.7.1 General
a) No paint shall be applied to surfaces containing physically adhering contaminants such as oil, grease, dirt, marking material, water-soluble
salts, wax, paint and temporary protectives, or to surfaces containing chemically bonded contaminants such as rust, mill scale, slag and
flux.
b) All surfaces which are painted shall be dry.
c) All traces of soluble salts and corrosive airborne contaminants shall be thoroughly washed from the surface prior to painting, and the
surface shall be dried and painted immediately afterwards.
d) Where surfaces are to be welded, unless otherwise specified, any paint shall not be applied within 75 mm of the weld position prior to
welding.
e) After the welding has been completed, the welds and adjacent parent metal shall be completely deslagged, and the surfaces shall then be
inspected and approved. All spatter shall be removed prior to the surfaces being painted. The weld area shall be abrasive-blasted and/or
ground and all contaminants such as flux shall be removed prior to the surface being painted.
f) Surfaces which are to rest on concrete or other floors shall receive all the prescribed coats of paint, and the paint shall be dry before the
members are erected.
g) Damaged paint areas shall be cleaned, rust spots removed and the surface again be primed so that the patch painting covers the damaged
areas and extends over a strip of 20 mm beyond each damaged area.
h) Where the shop coat is allowed to age for a few months before the next layer of paint is applied, light sanding with sandpaper or rubbing
with steel wool and scrubbing with clean water with a bristle brush shall be carried out.
i) Steel members embedded in concrete shall be entirely painted to a distance of 75 mm within the concrete measured from the concrete
outer surface, and the paint shall be dry before the members are installed.
j) The paint manufacturer's instructions shall be strictly adhered to.
k) Painted steel members shall be stacked so as to be off the ground.
l) Friction-grip surfaces shall not be painted unless specified otherwise.
A13.10.7.2 Applying the paint

Unless otherwise specified, paint may be applied either by brush, spray or roller method, or by any combination of these three methods, or by
powder coating.
Where brushes are used, they shall have sufficient body and length of bristle for spreading the paint in a uniform coat. Paint shall be evenly
spread and thoroughly brushed out. If brush marks are visible, it will be considered that the paint has been improperly applied, and the paint will
not be accepted.
On all surfaces which are inaccessible to painting by regular painting equipment, the paint shall be applied by bottle brushes, sheepskin
daubers, or by any other acceptable method so as to render the required coating of paint.
If spray methods are used, the operator shall be thoroughly experienced.
Where runs, sags, thin areas in the paint coat, or where air bubbles have formed or the paint has delaminated, or any skips exist, it shall be
considered as being unsatisfactory, and the Contractor will be required to repaint the surface.
A water trap and an air-regulating valve acceptable to the Engineer shall be furnished and installed on the equipment used for spray-painting.
Mechanical mixers shall be used for mixing paint properly when no ready-mixed paints are used. Prior to application, the paint shall be remixed
for a sufficient length of time to mix the pigment and vehicle thoroughly. Paint shall be constantly kept well stirred to keep the pigments in
suspension during its application. All skins in the paint shall be removed by screening. If it cannot be removed effectively, the paint and
paintwork already completed may be condemned at the discretion of the Engineer.
Paint shall not be applied when the temperature of the steel is not at least 3C above dew point or when the temperature of the steel is below
5C or above 35C, unless otherwise prescribed by the Engineer.

Paint shall not be applied in fog or mist, when it is raining or when rain is expected, or when the relative humidity is above 85 %.
A13.10.7.3 Protecting the works during painting operations

The Contractor shall protect all parts of the structure against disfigurement by spatters, splashes and/or smirches of paint or of paint materials.
The Contractor shall be responsible for any damage to or paint on or contamination to vehicles, persons or property, including plants and
animals, as a result of his operations, and he will be required to provide protective measures at his own cost to prevent such damage.
Any unsightly paint stains shall be removed by the Contractor at his own cost.
If passing traffic creates sufficient dust to harm or spoil the appearance of painted surfaces, the Contractor shall sprinkle the adjacent roads and
shoulders with water at his own cost, for a sufficient distance on each side of the location where the painting is being done, to keep the dust
away from freshly painted surfaces. The Contractor shall, at his own cost, also furnish and post appropriate temporary road signs and take other
necessary precautions to prevent dust and dirt from adhering onto freshly painted surfaces.
A13.10.7.4 Preparing surfaces for painting

Before paint is applied to any surface, the appropriate specified surface preparation shall be carried out in accordance with the relevant sections
of SANS 10064 or as specified herein.
A13.10.7.5 Painting structural steel

a) General
The surface preparation, priming and application of an undercoat shall be carried out under cover at the fabricator's works. Where possible, all
painting shall be done at the fabricator's works but, where this is unfeasible, the Engineer may permit the application of the finishing coats on the
site, in which case an undercoat shall be applied at the fabricator's works prior to the members being dispatched to the works.
Unless otherwise specified, the protection described in Clauses A13.10.7.5c), d) and e) shall be applied to all steel work.
b) Surface preparation
(i) New structures
After all cutting, drilling, welding and punching have been completed, it shall be ascertained that all sharp edges have been
uniformly rounded off and smoothed down. All physically adhering contaminants shall be removed and the surface shall then be
abrasive-blasted to Sa 2½ finish in accordance with BS EN ISO 8501-1. The profile limit of the surface finish shall be between 30
and 60 μm. The abrasive-blasting profile shall be measured in accordance with SANS 5772 and shall comply with SANS 10064.
No abrasive-blasting shall be done during rainy weather or when corrosive air conditions prevail.
Unless the application of a primer follows within 4 hours of abrasive blasting and before any oxidation of the prepared surface
takes place, the abrasive-blasted surface shall immediately after abrasive blasting be given one coat of a wash primer.
(ii) Existing structures
The surface preparation of existing steel structures shall be carried out on site in accordance with Clauses 3 and 4.4 of SANS
10064.
c) Primer
The prepared surface shall be given two coats of a zinc-chromate primer in accordance with SABS 679, type 1, grade II. The first coat shall be
applied within 12 hours in the case of wash-primed surfaces and within 4 hours, but before any oxidation of the surface takes place, in the case
of abrasive-blasted surfaces that have not been wash-primed. A fast-drying zinc chromate in accordance with SANS 679, type II, grade II, may
be used as primer. In all cases the dry-film thickness shall not be less than 30 μm per coat.
When steel has to be welded after the primer has been applied, the steel shall be left unpainted for a distance of 75 mm from the weld joint
unless a weldable type of paint has been used. The welds shall be treated in accordance with the instructions of Clauses A13.11.7.1 and
A13.10.7.5.
d) Undercoat
Where the finishing coats are to be applied on the site, the primed surfaces shall be given one coat of a universal undercoat with a suitable
colour in the fabricator's shop before despatch. The undercoat shall be applied as soon as the prime coat has dried sufficiently. The dry-film
thickness shall not be less than 25 μm.
e) Finishing coat
Two finishing coats of high-gloss structural paint (SANS 684, type A) of the specified colour shall be applied to leave a dry-film thickness of not
less than 25 μm per coat.
Where the finishing coats are applied on the site, the undercoat shall be lightly sanded and the members washed and cleaned of all
contaminants. The first finishing coat shall be applied as soon as the structural members are dry.
Where specified, the second finishing coat shall consist of a micaceous iron-ore-pigmented structural paint of the specified colour to a dry-film
thickness of not less than 30 μm. In all cases the second finishing coat shall be applied within 48 hours of the application of the first finishing
coat.
The dry-film thickness of the total paint system shall not be less than 110 μm when no undercoat is used and not less than 135 μm when an
undercoat is used. Where the second finishing coat is an iron-ore-pigmented paint, these thicknesses shall be increased by 5 μm.
f) Mating surfaces
When mating surfaces are brought together, both surfaces shall already have been covered with all the specified coats of paint, but, where this
is impossible, each surface shall be given a copious coating of primer and the surfaces drawn up while the paint is still wet.

g) Back-to-back members and areas not easily accessible
Back-to-back members and areas not easily accessible shall be fully coated with all the specified coats of paint up to and including the finishing
coats before erection.
h) Damaged areas
Damaged areas shall be treated as follows:
Sand down to bright metal and clean. Spot prime with two coats and sand down lightly when hard. Rinse off with water and allow to dry. Apply
two finishing coats.
i) Structural steel to be embedded below ground
Those parts of structural-steel members to be embedded in soil and all bases to a height of 500 mm shall be given two coats of an epoxy-tar
prime instead of the zinc-chromate prime specified for other surfaces.
A13.10.7.6 Painting guard rails

a) General
Guard rails are not painted unless otherwise prescribed.
b) Surface preparation and priming
All dirt, loose mill scale and loose corrosion products shall be removed by hand or power tools and all rust and mill scale by pickling, after which
the surface shall be rinsed and a neutralising rinse shall be applied, or the surface shall be phosphated.
c) Priming
Apply two coats of zinc-chromate primer to a dry-film thickness of not less than 20 μm per coat.
After the prime coats have hardened, the guard rails may be transported to the site.
d) Storage on the site
The primed guard rails shall be stored off the ground under cover and protected against rain and weather until erection. Guard rails shall be
stacked individually and not nested so as to prevent corrosion during storage. The finishing coats shall be applied as soon as possible and the
primed surfaces shall not be allowed to corrode as a result of prolonged exposure to the weather. Any guard rails showing signs of rust before
the application of the finishing coats shall be rubbed down with steel wool or fine sandpaper until all rust is removed, and it shall then be
recoated with a zinc-chromate primer.
e) Finishing
Before the first finishing coat is applied, the guard rails shall be thoroughly washed down to remove all traces of salt and/or other air-borne
corrosive materials and all dirt or other contaminants.
As soon as the rinsed guard rails are dry, a finishing coat of aluminium paint in accordance with SANS 802 or a white high-gloss enamel in
accordance with SANS 684 shall be applied to a dry-film thickness of not less than 25 μm. Within 48 hours this shall be followed by a second
coat as described before.
The guard rails shall preferably be given both finishing coats before erection, but, where this is impossible, the Engineer may permit the finishing
coats to be applied after the guard rails have been erected, provided that all mating surfaces and spots which are not easily accessible shall be
painted with the finishing coats before the guard rails may be erected.
The total dry-film thickness of all coats of the paint shall not be less than 90 μm. All damaged spots shall be treated as specified in Clause
A13.10.7.5h).
A13.10.7.7 Painting concrete

a) Surface preparation
The surface of the concrete to be painted shall be cleaned of all dust, loose particles, laitance, impurities and other deleterious materials, and
then washed and allowed to dry.
Unless the surface is to be covered with a bituminous paint, all cracks, holes and cavities shall be filled with grout or an acrylic filler.
b) Sealing and priming
The surface shall be sealed with an approved clear sealer which complies with CKS 564 and then primed with a primer consisting of an
undercoat diluted to 50 %.
c) Undercoat and finishing
An undercoat shall be applied after priming, followed by two finishing coats of the prescribed paint.
d) Bituminous paint
The surface shall be prepared in accordance with the requirements of Clause A13.10.7.7a). Before it dries out, a primer shall be applied in
accordance with the instructions of the fabricator of the bituminous paint.
After the primer has been applied, two coats of bituminous paint shall be applied at the rate of 0,75 l/m 2/coat. No paint coat shall be applied
unless the previous coat has dried out completely, and no paint shall be applied to the paintwork for so long as any moisture occurs on the
surface.

A13.10.7.8 Painting galvanised surfaces.
Galvanised surfaces shall be painted as specified in this section for steel surfaces, except that the surface preparation and priming shall be as
follows:
a) Surface preparation
Freshly galvanised surfaces shall be thoroughly scrubbed down with an approved galvanised-iron cleaner to remove all traces of the resin
protective coating.
The surface shall be washed down and scrubbed to remove all traces of grease, oil, dirt, etc.
b) Priming
Two coats of calcium-plumbate primer shall be applied to a dry-film thickness of at least 25 μm.
The undercoat shall follow within one week of the primer.
c) Treatment of site welds and damage to galvanising
Site welds to galvanised elements and isolated areas of damage to galvanising which is to be painted later or which has already been painted
may be repaired with low melting point zinc alloy after surface preparation. Alternatively, the whole of the affected area including exposed steel
substrate shall, after surface preparation, be given a coat of adhesion promoter which, when wet cleaned and finally dry, shall be overcoated
with two coats of Zinc Phosphate High Build Quick Drying Epoxy (2 pack) blast primer or Extended Cure Epoxy (2 pack) primer, minimum dry
film thickness of 75 microns each. The adhesion promoter shall not be applied over existing paints.
A13.10.7.9 Safety of painting operation

Some paints and preparation processes are harmful, including being flammable, carcinogenic and containing volatiles harmful to a person.
The supplier’s instructions regarding health and safety shall be strictly adhered to. This includes storage, handling, protective equipment,
breathing apparatus and masks.
Appropriate protective clothing and breathing apparatus shall be worn during preparation of surfaces to be painted.
A13.10.8.1 Measuring paint thicknesses
The dry-film thickness of paint shall be determined in accordance with SANS 2808.
At least 90 % of all thickness measurements shall comply with the minimum specified requirements. The thickness shall not in any case be less
than 70 % of the specified thickness.
In addition, painters shall be supplied with, and instructed to use, wet-film thickness gauges.

B13.10 PAINTING OF MINOR STRUCTURES
CONTENTS
B13.10.1 SCOPE
B13.10.3 GENERAL
B13.10.5 MATERIALS
B13.10.1 SCOPE
This Section covers the painting of structural steel to minor structures, guard rails, overhead road sign supports and other minor structures. Painting
of steel and composite steel bridges is covered in Section A13.12.
It excludes the corrosion protection of steel work exposed to aggressive or severe conditions.
This Section is suitable for labour enhanced construction activities and is subject to the Occupational, Health and Safety requirements,
particularly related to zinc chromate primers.
The provisions of Part A, shall apply, in addition to the following:
VOC = Volatile Organic Compounds
Low VOC paints contain < 50 g/litre of VOCs
B13.10.3 GENERAL

B13.10.5 MATERIALS
The provisions of Part A shall apply with the following amendments.
Paints shall comply with the requirements of the following specifications:
All primers, undercoats and paints shall contain low levels of Volatile Organic Compounds (VOC) and shall be non-toxic. Where toxicity or
absorption of the toxic element is low, such paints may be used provided that adequate precautions are taken during the application of the paints.
For labour enhanced work, Zinc-chromate primers for steel shall NOT be used. Alternatives such as zinc-phosphate primer shall be submitted
to the Engineer for approval.


The provisions of Part A shall apply with the following ammendments:
B13.10.7.1 Painting Structural Steel

Primer [= Clause A13.10.7.5c)]
Add:
An approved non-toxic primer shall be applied in accordance with the manufacturer’s instructions, for labour enhanced work.
B13.10.7.2 Painting Guard Rails

Priming [= Clause A13.10.7.6c)]
Add:
An approved non-toxic primer shall be applied in accordance with the manufacturer’s instructions, for labour enhanced work.

C13.10 PAINTING OF MINOR STRUCTURES
(i) Preamble
None.
pay items.
Painting C13.10.1 C13.9.1 - All applicable items
C13.10.1 Painting:
C13.10.1.1 (Describe structure/article) square metre (m2)
C13.10.1.2 (Describe structure/article) number (No)
C13.10.1.3 (Describe structure/article) metre (m)
C13.10.1.4 (Describe structure/article) ton (t)

The unit of measurement shall be the square metre of surface painted. Only the surface covered by the final finishing coat shall be measured.
The unit of measurement may also be the number of structures or articles painted, or a metre length of the structures or articles painted, or a ton of
the structures or articles painted, the quantities are calculated as specified in item C13.9.1.
The tendered rates shall include full compensation for surface preparation, applying all the coats of paint, repairing any damaged surfaces, and all
materials and construction plant necessary for completing the work.

C13.10.2 Extra-over item C13.10.2, using non-toxic materials:
C13.10.2.1 (Describe structure/article) square metre (m2)
C13.10.2.2 (Describe structure/article) number (No)
C13.10.2.3 (Describe structure/article) metre (m)
C13.10.2.4 (Describe structure/article) ton (t)

D13.10 PAINTING OF MINOR STRUCTURES
CONTENTS
D13.10.1 SCOPE
D13.10.2 GENERAL
D13.10.1 SCOPE
D13.10.2 GENERAL
a) Primers;
b) Undercoats; and
c) Finishing coats.



13.11 STRUCTURAL STEELWORK FOR MAJOR STRUCTURES
CONTENTS
A13.11.1 SCOPE
A13.11.3 GENERAL
A13.11.5 MATERIALS

A13.11 STRUCTURAL STEELWORK FOR MAJOR STRUCTURES

A13.11.1 SCOPE
This Section covers the manufacture, transport and erection of structural steelwork for major steel structures, e.g. steel bridge decks, composite
steel decks, and steel and composite steel cable-stay towers. It does not apply to minor steel structures such as sign gantries, which is covered
in Section A13.9.
A13.11.3 GENERAL
The specification below in general refers to British and European Standards. Equivalent international standards will be accepted subject to the
Engineer’s approval.

A13.11.4.1 Fabrication drawings
The Contractor shall prepare fully annotated fabrication drawings which shall be submitted to the Engineer for approval at least 6 weeks prior to
commencement of fabrication.
Fabrication drawings shall be A1 in size unless otherwise approved by the Engineer.
Drawings shall give all geometrical information including all dimensions, thicknesses, weld references/preparations, sizes, machining
requirements, material specifications/surface preparation, protective treatment and all requirements for fabrication of the element.
A13.11.5 MATERIALS
A13.11.5.1 General
All steels shall comply with the requirements of EN 10025, EN 10113, EN 10137, EN 10155, EN 10210 or BS 7668 and cross referenced
Standards therein.
Compliance shall be demonstrated by satisfactory testing in accordance with the requirements of the above standards.
Rimming steel shall not be used.
All steels shall be manufactured to a process acceptable to the Engineer to give required material properties.

The quality records of the plants manufacturing steels and products shall be provided together with other supporting information to show that the
proposed steel maker produces steel and products to the required quality.
A13.11.5.2 Steel plate

Steel plate shall have the required weldability, and when elements are to be bent to form a specified profile, or heat-treated steels shall be
manufactured with the required properties.
All steel shall be ultrasonically tested to Grade LC1 of EN 10160.
For welded cruciform joints transmitting primary tensile stresses through the plate thickness, on a band of width four times the thickness of the
proposed attachment, ultrasonic testing to acceptance level B4 of EN 10160 shall be carried out.
The thickness tolerance of plates shall be in accordance with Class A of EN 10029.
All steel shall be supplied with test certificates giving mechanical, fracture toughness (Charpy) and chemical composition.
Both Ladle and Product Analysis shall be carried out.
The Engineer's representative shall be given the facility to select samples for and to witness testing, and to inspect the surface condition of steel
products for acceptability prior to dispatch. Where weld repairs are proposed these procedures shall be submitted to the Engineer for approval.
The Contractor shall obtain from the steel manufacturer his proposal for steel making and the quality regime proposed for quality control and
traceability in respect of contract requirements, and these submitted to the Engineer for acceptance.
Where steel is to be processed from a Merchant, each product shall carry full traceability documentation.
A13.11.5.3 Rolled sections

The substitution of hot rolled sections by cold formed sections shall not be permitted.
A13.11.5.4 Shear studs

Steel for headed stud type shear connectors shall have a minimum yield stress of 385 N/mm2, a minimum tensile strength of 485 N/mm 2, and a
minimum elongation of 15 % prior to the cold formation of the head.
Steel for other types of shear connectors, shall, comply with the requirements of the EN 10025, EN 10113, EN 10137, EN 10210, and BS 7668.
A13.11.5.5 Bolts
Unless noted otherwise on the Drawings all bolts incorporated in the permanent works shall be HSFG bolts and shall comply with BS 4395, AMD
1843 and BS 4604
As an alternative, equivalent bolts may be supplied in accordance with SANS 1282.

A13.11.6.1 Welding equipment
All welding plant, cables, accessories, instruments, baking ovens and any ancillary equipment shall be maintained in good condition consistent
with the manufacturers’ specification for output performance.
As required by the Engineer the Contractor shall demonstrate that his equipment is in good working order. Where equipment is found to be
unreliable it shall be removed from use until its reliability can be demonstrated.
The Contractor shall ensure that earthing cables to all items of plant and equipment are of adequate cross section and all connections are
properly made and maintained to ensure current flow and to prevent stray arcing.
The Contractor shall provide all necessary equipment for measuring voltage, current, wire speed feed and temperature.

A13.11.7.1 Welding
a) General
All welding shall comply with the requirements of this specification and, where appropriate, EN 1011, SANS 10162 and other cross referenced
British Standards.
The Contractor shall establish all necessary processes, procedure specifications including procedure qualification records, trials and welder
qualification records, method statements, inspections, testing, calculations, reports on welding processes and other supporting documentation,
quality control procedures, and the Inspection and Test Plan covering all aspects of welding. These shall be subject to the approval of the
Engineer.
b) Welding processes
The Contractor is responsible for the design and selection of welding processes that ensure welded joints that have the necessary metallurgical
strength, ductility and fracture toughness properties to meet the Specification requirements.
Welding processes shall reliably produce satisfactory joints and where, in the course of production, a welding process is shown to produce
unsatisfactory results its use shall be discontinued.

Prior to adoption of a particular process the appropriate procedure trials shall be implemented and records of past performance of the welding
process supplied to the Engineer for his examination.
The following welding processes may be acceptable subject to the above criteria being satisfied:
• Manual Metal Arc
• Semi-automatic, automatic and mechanised metal-arc welding
• Submerged arc welding
• Gas shielded processes
• Un-shielded semi-automatic arc welding
"Electro-Slag" or "Fusarc" type welding processes shall not be permitted.
c) Consumables: Electrode specification
Consumables including electrodes, electrode wire, flux, and filler rods shall have suitable specifications to ensure that the weld metal will have
mechanical and chemical characteristics compatible with the parent metal and joint strength requirements and are suitable for the welding
process and position.
The Contractor shall establish suitable control systems to ensure that the storage, handling and use of consumables shall be strictly controlled in
accordance with the manufacturer’s requirements.
Consumables which show signs of damage or deterioration shall not be permitted for use and shall be removed from the Works.
Consumables shall be stored in dry heated conditions in their original containers, and in accordance with the manufacturers’ instructions.
Special treatment immediately prior to use, as recommended by the manufacturer shall be carried out to ensure that consumables are in the
optimum condition for the production of welds of the required quality.
To ensure that weld metal deposited by hydrogen controlled electrodes does not have an unacceptable hydrogen content, drying and baking
conditions shall be in accordance with the manufacturer’s instructions.
After baking, electrodes shall be protected from moisture absorption, and shall be temporarily stored in heated quires immediately prior to use.
The numbers of electrodes issued at any one time shall be strictly controlled consistent with work requirements.
Where electrodes are returned to stores these shall be treated in accordance with the manufacturer’s instructions before re-issue. Electrodes
exposed to poor storage, or that have become damp shall be removed from the Works.
Wire and cored electrodes shall be protected against damage and stored in dry heated conditions in accordance with the manufacturers’
instructions.
Flux materials shall be packed and stored to ensure that hydrogen controlled levels are achieved as required by the welding process to produce
weld metal with the required characteristics.
Special manufacturer’s instructions shall be fully implemented and demonstrated to the satisfaction of the Engineer.
d) Stud shear connectors: Welding and procedure trials
Stud shear connectors shall be welded in accordance with the manufacturer’s instructions, including preheating where necessary. Welding shall
not be carried out when the ambient temperature is below 00C or when the surface is wet. The studs and the surface to which the studs are
welded shall be free from scale and rust, metal spray, grease oil, paint, or other material which would adversely affect the quality of the weld.
The welds shall be visually free from cracks and lack of fusion and shall be capable of developing at least the nominal ultimate strength of the
studs.
Unless specified otherwise and before production welding of studs commences, procedure trials shall be carried out. The trials shall be made on
samples of material and studs representative of those to be used in the work. The samples of materials and studs shall be agreed with the
Engineer.
Where primers are to be applied to the work prior to fabrication, these shall be applied to the sample material before the procedure trials are
made.
e) Weld edge preparation
The preparation of joint faces shall be by a method acceptable to the Engineer so as to provide fusion faces with properties suitable for welding
with respect to chemical and mechanical properties.
Where flame cutting or shearing is used at least one of the following requirements shall be satisfied:
• The hardness of the cut edge does not exceed 350 HV 30 when tested in accordance with EN ISO 6507.
• The cut edge is entirely incorporated in a weld.
• The material from the edge is removed by grinding or machining to the extent of either 2mm or the minimum necessary to demonstrate
that the hardness on the edge does not exceed 350 HV 30 when tested in accordance with EN ISO 6507.
• The edge is softened by a suitable heat treatment approved by the Engineer and is shown by dye penetrant or magnetic detection
procedure to be free from cracks.
• Edge softening procedures shall incorporate recommendations of the steel manufacturer to ensure that proposed procedures are
compatible with as supplied steel characteristics.
In addition to these requirements flame cut edges shall be ground or machined to remove all visible signs of drag lines.

Fusion face profiles shall be to a geometry consistent with the production of the required quality of welded joint.
Fusion face/joint configurations shall be subject to weld procedure trails as part of the approval procedures required by this specification.
Fusion faces shall be free of all cracks or other irregularities which would lead to weld defects.
Alignment of fusion faces and root gaps shall comply with tolerances which are consistent with the proposed strength requirem ent and welding
process.
In the case of fillet welds, edges and surfaces to be joined shall be in as close contact as possible to minimise the risk of cracking. In no case
shall the gap exceed 2,0 mm. Where the gap exceeds 2,0 mm rectification proposals shall be submitted to the Engineer for approval.
Before fabrication is commenced, flame cutting trials shall be carried out using representative samples of materials to be used in the work,
samples of materials shall be subject to approval by the Engineer with appropriate documentation submitted.
made.
For flame cutting, trials on materials 20 mm thick shall be deemed to cover all material up to and including 20 mm thick, trials on material 40 mm
thick shall be deemed to cover all material over 20 mm thick up to and including 40 mm thick, material over 40 mm thick shall be tested for every
thickness increment of 10 mm.
f) Assembly for welding
Elements to be welded shall be brought together in the correct relationship to ensure that completion of deposition of weld metal respective parts
attain the require alignment.
Assembly of joints shall be arranged to give welders optimum access and versatility for the welding process.
g) Temporary attachments
The location and method of fixing of all temporary attachments shall be agreed with the Engineer. Welds for temporary attachments shall be
made in accordance with the same requirements for permanent welds.
The minimum length of weld shall not be less than 50 mm.
Temporary welded attachments shall be removed carefully by cutting or chipping clear of the parent material and the surface of the material shall
always be finished smooth by grinding followed by surface crack detection.
Temporary attachments shall not be removed by hammering.
Any scars from temporary attachments shall be made good to the satisfaction of the Engineer. Where weld repairs are required these shall
comply with the requirements for repairs to permanent welds.
h) Pre-heat
The pre-heating temperature is defined as the temperature of the parent plate before welding commences.
In multi-run welds the pre-heating temperature may be adjusted to a lower level depending on the arc energy input and sequence of welding
consistent with production of the required weld quality.
The required pre-heat temperature shall be applied to the parent metal in any direction from the joint preparation.
Where practicable the temperature shall be measured on the face opposite to that being heated.
The temperature shall be confirmed on the heated face at a time after removal of the heat source, related to the parent thickness to allow for
temperature equalisation.
Where fixed permanent heaters are in use and there is no access to the reverse face for temperature measurement, readings shall be taken on
the exposed parent metal surface immediately adjacent to the weld metal.
The combined thickness shall be determined as the sum of the parent metal thicknesses averaged over a distance of 75 mm from the weld line
with due allowance for significant changes in thickness adjacent to the 75 mm zone.
Depending on plate thickness and arc energy input, the required pre-heat temperature shall be determined in accordance with EN 1011.
i) Weld repairs
The Contractor shall submit for the Engineer's approval his proposals and procedures for repairs to welded joints.
If after repair a welded joint is still not satisfactory, the Contractor shall revise and re-submit his proposals for approval by the Engineer.
Where the joint is subsequently re-tested and found to be unsatisfactory the element shall be scrapped.
j) Protection from the weather
Surfaces to be welded shall be dry. Whenever there is any evidence of condensation taking place on metal surfaces warming shall be carried
out to remove such condensation.
In any case no welding shall be carried out on parent metal below 5oC.
When rain or snow is falling or during periods of high wind, necessary precautions shall be taken to protect outdoor welding areas. Draughts
shall be prevented from blowing along the bores of structural hollow sections when the bores will be penetrated.
Where gas-shielded welding processes are being used, sufficient screening shall be used to keep winds and draughts away from the welding
area to ensure that shielding gas is not disrupted.

A13.11.7.2 Shopwork
a) Dimensions and datums
The manufactured lengths of all items shall be such that, at datum temperature when the structure is complete and with full dead load applied,
the profiles of cables and roadway shall correspond to that given on the Contract Drawings.
The datum temperature shall be taken as 220C.
The Contractor shall, where he deems necessary, provide additional overlength to fabricated elements to ensure that correct geometry is
achieved. Where such overlength is provided it shall be trimmed on site to the required dimensions
b) Fabrication sequence
The Contractor shall take full account of the sequence of assembly and deposition of welds to minimise distortion and residual stresses to
ensure that the element on completion is within permitted fabrication tolerances.
During assembly all elements shall be adequately supported to minimise self-weight stressing and distortion.
The proposed sequence of assembly and welding shall be submitted to the Engineer for comment.
c) Tolerances on fabrication
All parts in a fabricated or other assembly shall fit together accurately within tolerances specified in this specification.
Where a machined plane surface is specified by the Engineer, it shall be machined within a deviation of 0,25 mm for surfaces that can be
inscribed within a square of 500 mm side.
Where the ends of stiffeners require to be fitted they shall be ground or machined as necessary to ensure that the maximum gap over 75 % of
the contact area does not exceed 0,25 mm.
All bolted splices shall be provided with steel packing plates where necessary to ensure that the sum of any unintended steps between adjacent
surfaces does not exceed 1,0 mm for HSFG bolted joints and 2,0 mm for other joints.
For welded butt joints any unintended deviation from planarity due only to a misalignment of parts shall not exceed the lesser of 0,15 times the
thickness of the thinner part or 3,0 mm. However, if due either to a different thickness arising from rolling tolerances or a combination of rolling
tolerances with the above permitted misalignment, this deviation exceeds 3,0 mm it shall be smoothed by a slope not steeper than 1 in 4.
Where machined butt joints are specified, abutting ends of respective elements shall be machined after fabrication is complete.
Due account shall be taken of post fabrication relaxation of the structure.
Elements shall be fabricated with due allowance for camber.
Tolerances on camber shall be agreed with the Engineer prior to fabrication and incorporated in the Fabrication Method Statement.
The checking of tolerances shall be carried out on the following basis unless otherwise agreed with the Engineer in writing.
All components shall be checked for deviations in accordance with the undernoted tolerance requirements.
The amount of checking may be reduced by agreement with the Engineer depending on the standard of fabrication actually achieved in practice.
Notwithstanding this all components shall be carefully examined by visual inspection and the results recorded.
Continued surveillance may require the checking of imperfections to be increased and the Contractor is required to fully address the checking
regime methodology in his fabrication Method Statement and Inspection and Test Plan.
Members and components of rolled and built-up sections shall be checked for compliance with tolerances given in BS5400 Part 6.
Imperfections shall be measured over the full extent of each gauge length and, the scanning device moved to ensure that panels or elements
are comprehensively measured as follows.
For plate panels the out-of-plane deviation at right angles to surface shall be measured over the full extent of the panel.
For stiffeners, the out-of-straightness at right angles to the plane of the plate, may be checked either on the plate attached to the stiffener or on
the stiffener, except in the vicinity of a site splice.
The outstand edge of a stiffener shall be checked for imperfections parallel to the plane of the plate.
At site joints plate panels shall be surveyed for imperfections for a distance of 1,0 m either side of the splice or up to the next boundary stiffener.
Stiffeners, at site joints, shall be checked for imperfections over the full extent of the panel containing the joint.
For cross frames the deviation shall be checked over the middle third length of the cross frame between each pair of webs.
For the web of a rolled section (Beam or Channel) the out of plane deviation shall be measured over a distance in the longitudinal direction equal
to the depth of the section.
Non-compliance with Tolerance Requirements and Rejection shall be based on the following:
• Plate Panels
Where permitted deviations are exceeded in plate panels, the maximum deviation shall be measured in the panel in question together with the
maximum deviations in adjoining panels.
• Stiffeners in plate panels
For stiffeners in plate panels the maximum deviation in the stiffener in question shall be measured as shall stiffeners in line in adjacent panels.
The measurements shall be submitted to the Engineer who will review the results and determine whether the component may be accepted, or
whether it may be acceptable with rectification, or whether the component shall be rejected.
The Contractor shall be responsible for preparing for approval by the Engineer proposals for rectification.
• Columns, struts, rolled or fabricated girders, cross frames and girders, webs of rolled sections
The maximum deviation need only be measured for the element in question, however depending on the relationship to other elements in terms
of structural interaction, measurement of maximum deviations of these may be required subject to the requirements of the Engineer.
The measurements shall be submitted to the Engineer who will review the results and determine whether the component may be accepted, or
whether it may be accepted with rectification or whether the component shall be rejected.
The Contractor shall be responsible for preparing for approval by the Engineer proposals for rectification.
Support of elements during inspection and measurement shall be representative and be of a similar manner to that in the completed structure.
On a completed element there shall be no external restraint or load during measurement of deviations.
Compliance with tolerances shall be checked at the following stages:
• On completion of fabrication and before any subsequent operation including surface preparation, painting, lifting, transport or erection,
the plate surface on the stiffener outstand shall be checked over the specified gauge length for the length of the stiffener.
• For plate panels and stiffeners on completion of site joints.
• For cross frames, and other parts in which deviations have apparently increased, for plate panels and stiffeners at limit of a specified
tolerance, on completion of site assembly and final erection.
d) Imperfection surveys
The Contractor shall prepare a programme for undertaking imperfection surveys to cover the various stages of fabrication, assembly and final
erection.
The Contractor shall prepare suitable forms and data sheets on which this information shall be recorded.
The Contractor shall make provision for Imperfection Surveys within an Inspection and Test Plan.
The Contractor shall undertake all surveys and present the results to the Engineer for acceptance.
Prior to commencement of surveys, the Contractor shall notify the Engineer, to provide the Engineer with opportunity to witness surveys as
required.
Until the standard of workmanship has been shown to be of a consistent quality, all steelwork shall be surveyed, thereafter the extent of the
survey may be reduced, notwithstanding that all steelwork shall be visually examined.
The foregoing shall be subject to the Engineer's approval.
(i) Preparation of edges, ends and surfaces
Any burring, abnormal irregularities or scales shall be removed.
(ii) Edges
Edges shall be either:
1. left as rolled, sawn, machined, machine flame cut; or
2. hand flame cut with subsequent grinding to a smooth profile; or
3. for stiffeners and gussets, both not more than 12 mm thick, sheared and subsequently ground to a smooth profile.
All external arrises shall be radiused to a minimum radius of 1,0 mm by grinding or filing.
(iii) Ends
Ends shall be either:
1. sawn, machined, machine flame cut; or
2. hand flame cut with subsequent grinding to a smooth profile; or
3. for stiffeners, of not more than 12 mm thick, sheared and subsequently ground to a smooth profile.
Where ends of stiffeners are required to be fitted they shall be ground, where necessary, so that the maximum gap over 60 % of
the contact area does not exceed 0,25 mm.
(iv) Flame cutting and shearing
Where flame cutting or shearing, as specified above is used at least one of the following
requirements shall be satisfied:
1. the hardness of the cut edge does not exceed 350 HV 30 when tested in accordance with EN ISO 6507;
2. the cut edge is not subjected to applied stress;
3. the cut edge is wholly incorporated in a weld;
4. the material from the edge is removed by grinding or machining to the extent of either 2,0 mm, or the minimum necessary to
demonstrate that the hardness on the edge does not exceed 350 HV 30 when tested in accordance with EN ISO 6507;
5. the edge is softened by a suitable heat treatment approved by the Engineer and is shown by dye penetrant or magnetic
detection procedure to be free from cracks;

6. the material is grade 43 steel and is not greater than 40 mm thick and edge preparation is by machine flame cutting.
In addition to the requirements of 1. to 6. a first quality cut as defined by EN ISO 9013 shall be achieved.
e) Trial assembly
Steelwork shall be subject to a trial assembly before transportation to site.
The extent of trial assembly shall be sufficient to ensure that all parts fit together accurately on final assembly in the correct geometrical
relationship.
The results of both trial and completed assembly shall be monitored in relation to specification requirements, and where unsatisfactory, the
fabrication methodology shall be modified.
f) Storage
The Contractor may store fabricated materials at the site, at an approved storage yard or at his shops, but he shall remain responsible for their
custody and care. He shall handle and store the materials in a careful and systematic manner, so as to prevent any damage, corrosion or loss.
Stored material shall not be permitted to rest on the ground or in water and shall be placed on suitable supports.
A13.11.8.1 Welding
a) Weld procedures
Written weld procedures are required for all welds and shall be subject to approval by the Engineer.
The following items of information shall be provided as appropriate:
• Welding processes to be used in making the joint.
• Parent metal specification, thicknesses of plate, and geometry of proposed joint.
• Whether weld is to be performed on site or in the fabrication shop.
• Proposals for cleaning, inter-run cleaning.
• Details of type, size, classification, specification for electrodes and other consumables.
• For manual metal arc-welding details of electrode size, welding current, fillet weld leg length, number of runs and electrode run-out
length.
• For semi-automatic, automatic and mechanised welding, the size of electrode, welding current, arc voltage, travel speed, wire feed
speed, electrode extension or fillet weld leg length and number of runs, rate of flow of shedding gases, rates of consumption of other
process materials.
• The temperature and time adopted for drying and baking of welding consumables before use.
• Diagram to show edge preparation, fit-ups, approximate number and disposition of runs in multi-run welds.
• Jigging arrangements to hold respective pieces in the correct relationship.
• Tack welding.
• Backing strips, material, method of fixing.
• Welding positions.
• Welding sequence.
• Preheat temperature and interpass temperature range, methods of confirmation and maintenance of required temperatures.
• Back gouging.
• Post-weld heat treatment.
• Matters arising from restraint and effects on weld metal and parent plate.
• Matters in relation to fracture toughness of weld metal and heat affected zone.
• Procedures to avoid cracking of welds.
• Package of information from which welders will work which must be sufficiently comprehensive.
All weld procedures shall be carried out in accordance with EN 288 to the satisfaction of the Engineer to demonstrate that the Contractor can
produce satisfactory welds.
Before fabrication is commenced, welding trials shall be carried out using representative samples of materials to be used in the work, samples of
materials shall be subject to approval by the Engineer and have appropriate documentation.
Welding trials shall demonstrate to the satisfaction of the Engineer the procedures to be adopted in the fabrication of the work, and as a
minimum shall comply with the requirements of EN 1011 & EN 288
made. Where galvanising or other metal coating of the material is to be applied to a part which is to be subsequently welded in the shop or on
site, the same coating shall be applied to the sample material before the procedure trials are made.
b) Welder qualification and testing
The Contractor shall ensure that all welders he employs on the Works are competent and qualified to carry out welds in accordance with
approved welding procedures.
The Contractor shall ensure that welds will only be performed by welders qualified to each specific weld procedure.
Approval testing and certification of welders shall be in accordance with EN 287.
c) Identification of welds
The Contractor shall implement a system to enable welds to be traced to the welder by whom it was made.
Hard stamping of steel is not permitted.
d) Procedure trials
(i) Testing of welding for structural steels
Non-destructive and Destructive Testing
With the exception of all weld tensile tests, non-destructive and destructive testing of welding shall be carried out as specified in
EN 288. The root bend and face bend tests specified in EN 288 shall have the weld root and the weld face respectively in tension
as described in the transverse bend tests of EN 910. Additionally, hardness tests shall be carried out on weld metal, heat affected
zone and parent material of a macro section from each weld procedure test sample and the results recorded and submitted to the
Engineer.
Charpy V-Notch impact tests for butt welds and heat affected zones of butt welds shall be carried out as given below.
Weld Metal and Heat Affected Zone (HAZ) Charpy V-notch Impact Test Requirements for Tension Areas.
e) Butt welds including corner or T-Butt welds parallel or transverse to main tension stress.
The minimum Charpy energy absorption requirements and test temperature shall be the same as that specified for the parent material joined. In
the case of parent material on each side of the joint which have different specified Charpy requirements, the weld metal requirements shall be
those of the parent material with the lower test temperature or, in the event that the test temperatures are the same, the higher energy
absorption requirement.
f) Heat Affected Zone (HAZ)
The fusion boundary region of the HAZ of butt welds, including corner or T-butt welds, which are transverse to and carry the main tension stress
shall have the following notch ductility requirements:
Heat welding input up to and including 5 kJ/mm – no test requirement
Heat welding input over 5 kJ/mm – as per parent metal.
g) Location and orientation of specimens and orientation of notch.
For Charpy tests in the weld metal the length of specimen shall be taken transverse to the line of the weld and the specimens notched so that
the line of the notch root is perpendicular to the plate surface and is on the centre line of the weld joint.
For symmetrical and asymmetrical double V double J and double bevel joint preparations the specimen shall be cut so that one face is
substantially parallel to, and within 3,0 mm of, the surface of the weld.
Additionally, for the asymmetrical preparation the specimen shall be taken from the side with the smaller preparation.
For single V, singled and single level joint preparations the specimen shall be cut so that one face is substantially parallel to and within 3,0 mm
of the root surface of the weld.
For Charpy tests in the fusion boundary region of the HAZ, specimens shall be taken with their length transverse to the line of the weld and
notched so that the line of the notch root is perpendicular to the original plate surface.
As far as possible, the notch at mid-thickness of the specimen should lie on the fusion boundary of the HAZ of the weld under test. The
specimens shall be cut so that one face is substantially parallel to, and within 3,0 mm of, the original plate surface.
h) Number of specimens
Initially, three specimens for each weld or HAZ under consideration shall be taken and depending on the test results for these specimens, a
further three specimens may be taken from the same joint.
i) Testing and acceptance criteria
The initial three specimens shall be tested and if the average of the three impact test results is less than the specified minimum average values,
or if one individual result is less than 70 % of the specified minimum average value, or if two results are less than the specified minimum average
value, then three additional test pieces from the sample shall be tested and the results added to those previously obtained and a new average
value calculated.
The new average value shall not be less than the specified minimum average value.
Not more than three of the total of six results shall be less than the specified minimum average value, nor more than two results less than 70 %
of the specified minimum average value and no individual result shall be less than 50 % of the specified minimum average value.
If the results fail to comply with the above requirements, the procedures concerned shall be rejected.
The cause of failure shall be established and depending on the causes either the procedure shall be modified without necessitating a new
procedure test, as given in EN 288 or a new procedure shall be established and approved by the Engineer.

j) Stud shear connectors
For each procedure trial, examination and testing shall be carried out on six specimens as follows:
Metallographic examination and hardness tests shall be carried out on macrosections prepared on a plane along the axis of the stud of three of
the specimens. The weld shall be free from macroscopic defects visible to the naked eye. The hardness of the weld metal shall lie in the range
150 HV 30 to 350 HV 30 when tested in accordance with EN ISO 6507. The hardness of the HAZ in the stud and the flange shall not exceed 350
HV 30 as given in EN ISO 6507 where the applied principal tensile stress at the ultimate limit state in the flange is equal to or greater than 100
N/mm2 or 400 HV 30 where the flange is in compression or the applied principal tensile stress at the ultimate limit state in the flange is less than
100 N/mm2.
Each of the remaining three studs of the sample shall be bent to a lateral movement of the head of approximately half of the height of the stud
and then bent straight again without failure of the weld.
k) Production tests
(i) Destructive Testing of Welding for Structural Steel
• Production Test Plates
Unless specified by the Engineer, approximately one in five pairs of "run-off" plates for transverse butt welds in tension flanges
and one in 10 pairs for other butt welds shall be production test plates.
The combined size of each pair of production test plates shall be adequate for the number and size of specimens to be tested.
The material quality of the run-off plates shall be the same as that of the plates to be welded.
On completion of the welds the "run-off" production test plates shall not be removed until they have been marked in a manner,
agreed by the Engineer, to identify them with the joints to which they are attached.
Testing
The following tests shall be carried out on the production test plates.
• Transverse Tensile Test
One transverse tensile test comprising sufficient specimens to cover the full plate thickness shall be made in accordance with
EN 895 and the tensile strength shall be not less than the corresponding specified minimum value for the parent plate.
If any specimen fails to meet the test requirement then a further test shall be made from the same production test plate.
If any specimen from this further test fails to meet the test requirement then the joint shall be rejected.
• Bend test
Bend tests shall be made in accordance with EN 910. For materials less than 10 mm in thickness one transverse root bend test
and one face bend test shall be made.
For material 10 mm in thickness and over, one side bend test comprising sufficient specimens to cover the full plate thickness
shall be made.
The diameter of the former and the angle of the bend used in the test shall comply with the requirements of EN 288.
On completion of bending any defects in the tension surface of the test specimen shall be investigated and their cause
established before the specimen is either accepted or rejected.
Slight tearing at the edges of the test specimen shall not be a cause for rejection.
If any specimen fails to meet the test requirement then a further test shall be made from the same production test plate.
If any specimen from this further test fails to meet the list requirement then the joint shall be rejected.
• Charpy V - notch impact test
Charpy V-notch impact tests shall be made in accordance with EN 875 on weld metal in butt welds transverse to and carrying
the main tension stress.
Additionally, where specified by the Engineer, Charpy V-notch impact tests shall be made on the fusion boundary region of the
HAZ and shall comply with the requirements of (d) (i) above.
Re-welding and Re-testing
In the event of failure to meet the testing requirements of above the results shall be submitted to the Engineer who will
determine whether the joints concerned and those represented by the tests may be accepted without additional work, or
accepted subject to other satisfactory tests or additional work, or rejected.
Rejected joints shall be cut out, re-welded and the tests repeated.
Non-Destructive Testing of Welding for Structural Steel.
Testing requirements are given in A13.11.8.1f).
In the case of b), and c), the particular length of welds to be tested shall be agreed with the Engineer.
Where specified by the Engineer, ultrasonic testing of support diaphragms or bearing stiffeners adjacent to welds, plates in box
girder construction adjacent to web/flange welds material at cruciform welds or other corner details shall be carried out after
fabrication.
Any lamination, lamellar tearing or other defect found shall be recorded and reported to the Engineer for his decision.

l) Quality of welds
Welded joints require to be free from defects which would impair the performance of the structure.
Sub-surface and surface defects shall be in accordance with the requirements given in BS5400 Part 6 for fillet welds and for butt welds.
Non-destructive testing of welds shall be carried out as follows:
Element Extent Acceptance Quality Category
1. Transverse Butt Welds 100% US A
100% MPI
2. Longitudinal butt welds 10% US B
10% MPI
3. Fillet Welds 10% MPI B
4. Fillet welds at bearing stiffeners, at central 100% MPI A

movement joint, & cable stay anchorages
m) Stud shear connectors weld testing

Stud shear connectors shall be subjected to the following tests.
The fixing of studs after being welded in position shall be tested to the satisfaction of the Engineer by striking the side of the head of the stud
with a 2,0 kg hammer.
Any stud selected by the Engineer shall be capable of being bent by striking the side of the head of the stud with a 6,0 kg hammer until its head
is displaced approximately 0,25 times the height of the stud. The stud weld shall not show any signs of cracking or lack of fusion. Satisfactory
studs shall not be bent back. The Contractor shall ensure that the direction of the test does not interfere with the fixing of reinforcement.
All fixed studs shall be subjected to the hammer ring test.
Where studs fail the hammer ring test, the Contractor shall increase the number of shear studs on that element of steelwork by 10 % together
with replacing the faulty stud. The extra connectors shall be placed in positions agreed by the Engineer
A minimum of 1 % or 2 No, whichever is greater, of the studs attached to any one element of steelwork shall be tested.
Should a stud fail the bend test, 10 further studs shall be tested on the same item of steelwork. If any of the further studs fail the test, the
Contractor shall submit a revised weld procedure for approval and shall carry out weld procedure trial at his own cost.
Further to the requirements above, before the start of each day’s welding, three studs shall be welded to a plate of the same thickness as the
steelwork being worked on and tested in accordance with the above requirements. If any of these studs fail, a further set of three studs shall be
welded and tested until satisfactory results are obtained, before any studs are welded to the permanent steelwork.
n) Supervision
All welding shall be carried out under the control and supervision of appropriately qualified and experienced supervisory staff.
A13.11.8.2 Shopwork
a) Supervision
All fabrication and assembly shall be carried out under the supervision of suitably qualified and experienced staff with particular experience of
the type of fabrication and assembly required by this contract.
Proposals for supervision and management structure of the supervisory team shall be submitted to the Engineer for acceptance 6 weeks prior to
commencement of the fabrication process.
b) Dimension control
All measuring instruments shall be calibrated against reference standards acceptable to the Engineer.
Only calibrated instruments shall be used in the works.
The Contractor shall maintain a continuous record of calibration of each instrument; the Contractor shall submit for the Engineer's approval his
proposed method and programme for instrument servicing and control of calibration.
Reference standards for calibration shall be in Laboratories approved by the Engineer.
For each element a full record of dimensions, pre- and post fabrication shall be prepared by the Contractor and submitted to the Engineer.
These shall be provided for the Engineer's acceptance, and the Contractor shall provide full access and assistance to enable the Engineer to
check any dimensions as required.
The Contractor shall make due allowance in his programme for time required by the Engineer to check dimensions.
The accuracy of equipment for scanning imperfections shall be calibrated to  0,5 mm.
c) Fabrication Method Statement
The Contractor shall prepare a detailed method statement with explanatory diagrams to demonstrate his intended sequence of operations in
fabrication and assembly.
The method statement shall be submitted to the Engineer for approval, and shall be re-submitted if revisions are required by the Engineer.
The method statement shall be submitted at least six weeks prior to commencement of fabrication.
d) Traceability
The Contractor shall operate a full documentation and control system designed to ensure that all elements have full traceability from material
production through fabrication to final assembly, protective treatment, and erection.
Ingots, billets, slabs, plates, steel sections, bars and other products shall be clearly marked with identification marks to enable finished steel to
be traced to the cast from which it was made. Grades of steel shall be clearly identified.
The proposed system shall be subject to approval by the Engineer, and 6 weeks prior to commencement of work details of the proposed system,
including its supervision, shall be submitted.
The traceability system will be subject to independent audit by the Engineer.
Aspects covered by the traceability system shall be sufficient in extent to demonstrate adequate control.
The system shall embrace:
• production of steel plate
• marking of plate; control in stockyard
• sub-division of parent plate into sub-elements
• preparation
• dimensional control from material cutting through to final assembly, checking of dimensions at each stage
• welding process
• welder to weld identification
• electrode manufacture, storage and subsequent use
• Imperfections surveys
• Non-conformance controls and rectification
• Protective treatment
• Trial assembly
• Final assembly
• Erection
• All testing and inspection records
Further items as necessary are to be incorporated to ensure that all aspects of fabrication, assembly and erection are covered.
e) Inspection
The Contractor is responsible for preparation and implementation of an Inspection and Test Plan for the fabrication of all elements of the bridge.
The Inspection and Test Plan shall address all operations, stages involved, inspection and testing required at each stage, quantum of inspection
and testing to be carried out, the type of documentation record to be produced, hold points, and points for independent inspection and testing by
the Engineer.
The Inspection and Test Plan will be submitted to the Engineer for approval and identification of inspection and testing points required by the
Engineer 6 weeks prior to the commencement date of manufacturing.

B13.11 STRUCTURAL STEELWORK FOR MAJOR STRUCTURES
CONTENTS
B13.11.1 SCOPE
B13.11.3 GENERAL
B13.11.5 MATERIALS
B13.11.1 SCOPE
This Section covers the manufacture, transport and erection of structural steelwork for major steel structures, e g steel bridge decks, composite
steel decks, and steel and composite steel cable-stay towers. It does not apply to minor steel structures such as sign gantries, which is covered
in Section A13.9. Due to the specialist nature of the activities associated with this work, it is deemed unsuitable for labour enhanced work.
B13.11.3 GENERAL

B13.11.5 MATERIALS



C13.11 STRUCTURAL STEELWORK FOR MAJOR STRUCTURES
(i) Preamble
None.
pay items.

C13.11.1 Supply, fabrication and erection of steelwork (location, member, grade and type ton (t)
identified)
The unit of measurement shall be the computed mass of the finished member comprising plates, rolled sections, shear connectors, stiffeners,
cleats, packs, spliced plates, access hatches, doorways and all fittings, without allowance for tolerances for rolling margins and other permissible
deviations from standard masses or nominal dimensions and excluding the masses of welds, bolts, nuts, washers, rivets and protective coating.
No deductions shall be made for notches, cope holes, bolt and rivet holes, and the like, which are less than 0,03 m2. No allowance will be made
for overlength provided in order to achieve the correct line and level.
The tendered rate shall include for the production of detailed fabrication and shop drawings.
The computed mass of rolled steel shall be determined from the dimensions given on the contract drawings and the density of steel given as
7850 kg per cubic metre.
The Contractor should check the masses and quantities of steel for the various grades himself. Should the Engineer instruct a design change
involving a change to the mass of the steel shown in the contract drawings, then the unit price for that unit or piece only may be revised.
For ease of measurement, of Fabrication and Erection of Steelwork at each location specified above, measurement shall be identified by
member and steel grade.
The tendered rates shall include full compensation for the following:
(a) supply of steelwork;
(b) delivery of steelwork to site;
(c) labour and plant associated with erecting and fixing the steelwork
(d) examining and checking for segregation, laminations, cracks and surface flaws and carrying out any remedial measures required by the
Engineer in respect to these defects;
(e) weld testing in accordance with the specification,
(f) cutting, marking off, drilling, notching, machining, treatment of outside arises, smoothing of slopes, form fitting, end and edge preparation
and cambering;

(g) bolting, assembling and pre-heating;
(H) welds, packing plates, bolts (including holding down bolts), nuts and washers required to fabricate and to complete the erection and
installation on site, together with spares and service bolts, drifts, draw up cleats and the like; pre-production procedural trials;
(i) welder approval trials and provision of certificates;
(j) checking of deviations in plate panels and rolled and built–up sections and of alignment at joints, including taking measurements and
observations and recording and supplying one copy of the records to the Engineer;
(k) preparation and supply of marked erection drawings, marking members for identification and delivery in matching sequence.
(l) Temporary bracing or stays to prevent displacement including the provision and removal of temporary attachments;
(m) Proving dimensions, cambers and profiles and alignment of joints through trial erection;
(n) Match-marking members as required for permanent erection;
(o) Dismantling trial erections;
(p) Modification and refitting of members as a result of trial erection;
(q) Permanent bolted and welded connections including the provision of preheat and shelters for welding;
(r) Erection to the correct line and level,
(s) All incidental items to completely finish the work.
C13.11.2 Miscellaneous metalwork (location and member to be specified) number (No)

Miscellaneous metalwork shall comprise items of metalwork incorporated into structures necessary to provide access for inspection and
maintenance and shall include ladders, access covers and frames, mesh panels, walkway panels, screens, grilles, handrailing, kick plates,
material hoists, fall arrest systems and the like.
Items of metalwork which are included in the computed weight of fabricated items or are included in the measurement of other items shall not be
measured as miscellaneous metalwork.
The tendered rate shall include full compensation for miscellaneous metalwork including the delivery and supply of all materials, labour, plant,
permanent and temporary fixings, bolts, nuts, washers, rivets, frames, holding down systems, support steelwork and restraints and where
specified in the Contract drawings, Contractor’s design and checking services, necessary to design and erect the miscellaneous metalwork,
installation, testing, commissioning and documentation.

D13.11 STRUCTURAL STEELWORK FOR MAJOR STRUCTURES
CONTENTS
D13.11.1 SCOPE
D13.11.2 GENERAL
D13.11.1 SCOPE
D13.11.2 GENERAL
(a) Structural steel: each type and batch;
(b) Other structural steel materials including shear studs, bolts, nuts, washers, welding material, etc.;
(c) Welding procedures; and
(d) Welder qualification and testing.



13.12 STRUCTURAL STEEL PROTECTIVE TREATMENT OF MAJOR
STRUCTURES
CONTENTS
A13.12.1 SCOPE
A13.12.3 GENERAL
A13.12.5 MATERIALS

A13.12 STRUCTURAL STEEL PROTECTIVE TREATMENT OF MAJOR

STRUCTURES
A13.12.1 SCOPE
This Section covers the protective treatment of structural steelwork for major steel structures, e.g. steel bridge decks, composite steel decks,
and steel and composite steel cable-stay towers. It does not apply to protective treatment of minor steel structures such as sign gantries, which
is covered in Section A13.10.
A13.12.3 GENERAL
The Specification below in general refers to European and British Standards. Equivalent international standards will be accepted subject to the
Engineer’s approval.
The Contractor shall establish implementation procedures which shall ensure the integrity of the protective treatment systems to be applied to
the various elements of the bridge. Both the supplier and applicator of the protective treatment shall have a quality system in accordance with
ISO 9001.
The Contractor shall prepare, for approval by the Engineer, method statements, procedures and Inspection and Test Plans covering each aspect
of protective treatment from paint manufacture (including paint manufacture quality control systems, testing and traceability), storage of paint,
paint system application procedure trials, the various stages of steel preparation, paint coat application, ambient conditions control, inspection,
testing, restoration and repair, compliance with all health and safety requirements and reporting of results.
Surface preparation and protection against corrosion of steelwork shall be carried out in accordance with the undernoted Clauses with due
account taken of the design and fabrication of the structure.
The Contractor shall establish measures to contain people, plant, materials, dust and debris during preparation and application of protective
coatings.

A13.12.5 MATERIALS
A13.12.5.1 Paint and similar protective coatings
The term paint shall be deemed to refer also to similar protective coatings including specialist coatings such as grease paints.
All paints incorporated in the Permanent Works shall conform to the formulations which have been registered by the manufacturer. All materials
comprising the paint system shall be supplied from a single manufacturer
All paints shall be supplied in sealed containers of not more than 5 litres capacity and these shall be used in order of delivery. Each container
shall be clearly marked on the side to show the name of the manufacturer, registered description of the material (including purpose, e.g. whether
primer, undercoat or finish), colour, paint manufacturer's reference number, batch number and date of manufacture. Where date of manufacture
is coded, the Contractor shall provide the Engineer with the code key.
The Contractor shall ensure that the properties of the paints he has selected are suitable for the conditions in the shops and on site, including
temperature and humidity, and that he is able to apply the paints satisfactorily to all parts of the structure in these conditions.
All paints forming any one protective system or overlapping systems, shall be obtained from the same manufacturer, as named by the
Contractor on the approved Paint System Data Sheet, see Clause A13.12.8.4, submitted by the Contractor.
A13.12.5.2 Storage requirements and keeping periods for paints

On delivery to the shops or site, paint shall be unloaded directly into one or more secure paint stores. Unless otherwise agreed by the Engineer,
paint shall be stored within 100 metres of the painting area. Insulation and means of heating and ventilating shall be provided as necessary to
maintain the temperature of paint stores between 5°C and 27°C.
If at any time or place paint in tins, painters' kettle or airless spray containers is allowed to reach temperatures outside the 5° and 27° limits, the
paint shall be discarded and not used in the Permanent Works. The Contractor shall also implement any additional storage restrictions
recommended by the paint manufacturer.
Paint which has not been used within the shelf life recommended by the manufacturer or within 18 months of the date of manufacture, whichever
is the lesser, shall be discarded and not used in the Permanent Works.
Chemically or moisture cured paints shall not be used after the expiry of the pot life or at the end of each working day/night whichever is the less.
All other paints in opened tins or open containers including painter’s kettles shall be returned to store and kept in sealed containers with not
more than 10 % ullage.
Exceptionally, and subject to agreement by the Engineer, components of Polyamide-cured Epoxy paints may have their keeping period
extended to 24 months provided that the Contractor returns the paints to the paint manufacturer and ascertains that the manufacturer examines
the contents of each tin and reconstitutes the paints as necessary so that such paints are equal in all respects to the paints described in the
Contract.
Each tin of reconstituted paint returned to the shops or site by the manufacturer shall have an additional label affixed stating 'Extended Keeping
Period to (date)'. The previous date marking shall remain and not be obscured. Testing in compliance with
Clause A13.12.8.2 shall apply to reconstituted paints.

A13.12.7.1 General requirements for surface preparation (shop & site work)
Prior to blast cleaning or abrading steel surfaces or overcoating painted or galvanised surfaces, contamination shall be removed by wet
cleaning. Solvents shall not be used.
Clean water shall be used for cleaning and rinsing provided it does not leave harmful residues.
Only cleaning agents which do not leave harmful residues on the surface after final rinsing shall be used for cleaning.
Surface preparation shall be continued until the required standard has been achieved. The surfaces are required to be free from condensation,
oil, grease, dust residues and detrimental contamination such as chlorides and sulphides. These can be tested using the procedures of EN ISO
8502.
Weld spatter shall be removed from areas to be galvanised or protected by metal spray or paint. Weld spatter shall be removed before blast
cleaning.
After dry surface preparation of internal surfaces and before any wet cleaning, all dust and debris shall be removed by sweeping and vacuum
cleaning.
Before application of each coat of paint, the Contractor shall ensure that the surfaces:
• meet the required standard of preparation;
• are free from harmful residues including mortar, concrete, dust, grit and paint degradation products;
• are free from detrimental contamination;
• are free from moisture detrimental to the coating to be applied.
Joints shall be sealed in accordance with Clause A13.12.7.5b)(viii) & (ix)

Paint coats shall be free from embedded metallic or other foreign particles and such adherent matter on metallic coatings or painted surfaces
shall be immediately removed and coatings damaged in the process restored.
The final shops coats on external surfaces shall be wet cleaned on site to remove any harmful residues and contaminants.
A13.12.7.2 Materials and methods for surface preparation

a) Dry blast cleaning in the shops
The following materials shall be used:
Chilled-iron grit complying with EN ISO 11124-2, high carbon cast-steel or grit complying with EN ISO 11124-3 with a hardness value greater
than 650 HV, fused aluminium oxide complying with EN ISO 11126-7; non-metallic abrasive such as fused aluminium oxide to EN ISO 11126-7
almandite garnet to BS 7079-F10, copper slag to EN ISO 11126-3 or recycled glass complying with EN ISO 11126-7.
Grades for metallic abrasives shall comply with the following:
Profile Grade
Fine G050 or S060
Medium G070 or S100
Coarse G100 or S120
The particle size of metallic abrasive in plant or equipment shall not exceed the maximum of the relevant grade as specified above.
Before the start of blast cleaning and during blast cleaning the Contractor shall ensure that the abrasive is free from matter which could leave
detrimental contamination on the surfaces to be coated.
b) Surface preparation by abrading in the shops or on site
Any matter or paint which is difficult to remove by abrading alone shall be dislodged by scraping, by hand or power wire-brushing and shall be
completed before abrading the areas so affected.
Abrading shall be by use of abrasive paper or other material or a flexible abrasive disc mounted on a power driven flexible pad and may be used
to remove weld spatter. Wet abrading may be used for the preparation of finishes over sound undercoats, over unsound systems over
galvanising, or galvanising. Wet abrading shall not be allowed to come into contact with exposed thermally sprayed metal coatings.
All equipment, tools, abrasive sheets and discs and shall be suitable for the purpose. The use of hard grinding wheels for abrading shall not be
acceptable.
A burnished appearance caused by polishing in paint, rust or dirt shall not be accepted.
Corroded steel or unsound metal coatings which have been prepared by abrading to bright steel or bright metal coating, and blast cleaned,
where appropriate, shall be protected by the primer and next coat of the paint system prior to cleaning or preparation of adjacent surfaces.
c) Surface preparation by wet cleaning in the shops or on site
Wet cleaning shall be carried out by scrubbing with a stiff-bristled brush using water and an approved cleaning agent or a pressure washer and
immediately after cleaning, surfaces shall be thoroughly rinsed.
d) Surface preparation by dry cleaning in the shops or on site
Surfaces shall be cleaned by scrubbing with a dry stiff-bristled brush.
e) Surface preparation by dry blast cleaning on site
Metallic grit abrasives shall comply with section (a) of this Clause and shall be used for dry blast cleaning of small areas to be metal sprayed, as
at site welds, at areas prepared to clean steel or areas where a metal spray is to be restored, as indicated in Clause 13.12.7.4(b). The
Contractor shall ensure that the grade and particle shape of proposed non-metallic abrasives are adequate for the purpose intended: non-
metallic abrasives shall not be recycled.
f) Surface preparation by low or high pressure wet blast cleaning on site
Subject to the Engineer's approval an adjustable low pressure air/water/abrasive system shall be used with the air/water pressure at the nozzle
limited to 7,0 kgf/cm2 maximum and shall be fully adjustable. The quantity of non-metallic abrasive to be fed into the air/water mixture shall be
fully adjustable by remote control and the air, water abrasive mixture thoroughly mixed and projected by a single bore nozzle. Inhibitors shall not
be permitted.
Subject to the Engineer's approval an adjustable high pressure water system shall be used with the water pressure at the nozzle limited to 562
kgf/cm2 for high pressure or between 1750 and 2860 kgf/cm2 for ultra high pressure. The system shall incorporate a mechanical metering device
controlled by the operator at the nozzle, to regulate from zero to the maximum quantity of non-metallic abrasive being fed into the water.
g) Surface preparation by combined wet/dry blast cleaning on site
Wet blast cleaning using the low pressure air/water/abrasive system in compliance with the above Clauses shall be followed by dry blast
cleaning as specified above.
The specified standard of surface preparation shall be achieved by wet blast cleaning and washing; dry blast cleaning shall be used to remove
flash rusting or to restore surface preparation to the required standard.

h) Other requirements
Within 1 hour of wet blast cleaning, the whole of the cleaned surface shall be thoroughly washed using the blast cleaning equipment with air and
water and any remaining deposits of abrasive and debris removed by the same process before the end of the working day. After washing, the
surfaces shall be free from all particles of dust and debris. Tests for freedom from detrimental contamination shall be made after the washing.
Where it is intended that surface preparation is to be by dry blast cleaning and, on adjacent surfaces, by wet cleaning and or abrading, then after
dry surface preparation of internal surfaces and before any wet cleaning the wet cleaning and any abrading shall be carried out first.
When combined wet/dry blast cleaning has been specified instead of dry blast cleaning only, the above sequence may be reversed. Wet blast
cleaned areas shall be cleaned and rinsed prior to dry blast cleaning.
i) Grinding after surface preparation in the shops or on site
Subject to approval of the Engineer grinding wheels and discs shall be of the size, shape and grade of coarseness and speed appropriate to the
particular operation.
A13.12.7.3 Workmanship standards for the surface preparation of steel by blast cleaning,
abrading, grinding and cleaning
The surface profile to be achieved by blast cleaning, either 'Fine', 'Medium' or 'Coarse', as appropriate, shall be within the limits set by the
Surface Profile Comparator for the Assessment of Abrasive Blast Cleaned Surfaces, conforming to EN ISO 8503: Part 1.
Blast cleaned surfaces shall be virtually free from sharp spikes of parent metal defined as 'rogue peaks' formed by the impact of abrasive
particles and which project above the blast cleaning profile. Any 'rogue peaks' which in the opinion of the Engineer would be detrimental to the
protective system shall be removed.
'Hackles' and inclusions caused by the rolling process, visible after blast cleaning, shall be removed. Affected surfaces shall be prepared by
grinding or abrading to bright steel in compliance with Clause A13.12.7.6 where appropriate. Sharp edges shall be rounded. If metal spray is to
be applied the surfaces shall then be blast cleaned.
Steel surfaces to be prepared by any of the methods described in the Contract shall be such that after surface preparation the surfaces are free
from detrimental contamination and conform to the following.
a) Visual cleanliness
Surface preparation by blast cleaning shall be to one or more of the following standards of visual cleanliness:
• 'Clean steel' SA3 to EN ISO 8501 – 1
Appearance: There shall be a blast cleaning pattern overall. The surface profile shall be free from mill scale, rust and foreign matter when
viewed through a X10 illuminated magnifying glass.
• 'Clean steel' SA2½ to EN ISO 8501 - 1
Appearance: There shall be a blast cleaning pattern overall. The surface profile shall be free from mill scale, rust and foreign matter when
viewed by normal vision.
• 'Bare Steel' (blast cleaned or abraded)
Appearance: The surface shall be free from all rust scale, loose rust and loose mill scale.
After surface preparation by blast cleaning to SA3 or SA2½ the surface profile shall be virtually free from embedded abrasive particles when
viewed through a 10X illuminated magnifying glass of a type approved by the Engineer. Surfaces assessed as unsatisfactory in this respect by
the Engineer shall be blast cleaned again with fresh abrasive. Another abrasive complying with the Specification may be used if necessary.
b) 'Harmful residues' or 'detrimental contamination':
Surfaces shall be deemed to be free from 'harmful residues' or 'detrimental contamination' after surface preparation when, in the opinion of the
Engineer, any such remaining matter will not reduce the required durability of the specified protective system.
c) 'Bright steel':
Surfaces free from defects or prepared to this standard by grinding or abrading shall have an overall bright appearance.
A13.12.7.4 Workmanship standards for the surface preparation of coated steelwork by blast
clearing, abrading, grinding and cleaning
a) Before overcoating
Before overcoating, surfaces shall be free from:
(i) any visible gloss which may, in the opinion of the Engineer, prevent adequate adhesion of the next coat
(ii) any unsound paint down to sound paint
(iii) any unsound paint down to clean steel
(iv) any unsound paint down to bright steel
(v) any unsound paint down to sound metal coating
(vi) any unsound paint down to bright metal coating
(vii) any unsound metal coating down to sound metal coating
(viii) any unsound metal coating down to bright metal coating
(ix) any unsound metal coating down to clean steel
(x) any unsound metal coating down to bright steel
(xi) detrimental contamination

b) Definitions of terms
Definitions of terms used in describing the above standards of workmanship are as follows:
(i) 'Clean steel', as in Clause A13.12.7.3a)
(ii) 'Bright steel', as in Clause A13.12.7.3c)
(iii) 'Free from detrimental contamination', as in Clause A13.12.7.3b)
(iv) 'Bright metal coating' resulting from abrading, a metal coating whose surfaces are free from all corrosion products and of bright
appearance overall
(v) 'Unsound metal coating', a metal coating showing signs of disruption, inadequate adhesion or penetration by rust or other corrosion
products
(vi) 'Sound metal coating', a metal coating which complies with Clause A13.12.7.8b) including such a metal coating which has been blast
cleaned but which has a reduced thickness in accordance with Clause A13.12.7.7.
(vii) 'Unsound paint', paint showing signs of disruption, rusting through, having inadequate adhesion or covering rust scale, loose rust, loose
mill scale or other detrimental products
(viii) 'Sound paint', paint which is sound down to a metal substrate.
Definitions of terms used in Clauses A13.12.7.5, A13.12.7.6 and A13.12.7.7 are as follows:
(i) 'Restored' coatings. When paint or similar coatings or metal spray coatings are to be restored, the standard of surface preparation and
coating material shall comply with the original standard. Damaged or failed paint systems over metal spray shall be restored using dry
blast cleaning. The thickness of any underlying metal spray or paint coating which may have been reduced in thickness during surface
preparation shall be brought up to specification.
(ii) 'Restored' surface preparation. The original standard shall be obtained. When further metal spray coating is to be applied, the surface
of the existing metal spray coating shall be restored by dry blast cleaning with metallic grit abrasive to sound metal coating.
(iii) 'Local failure'. An isolated breakdown of a protective coating or system due to extraneous causes excluding mechanical damage.
c) Permitted residual metal sprayed aluminium and zinc
When 'clean steel' is exposed through a metal spray coating during remedial surface preparation, remnants of sound aluminium metal spray
coating may, subject to the agreement of the Engineer, be retained in a blast cleaning profile; also, subject to the agreement of the Engineer, be
retained in a blast cleaning profile; also, subject to the agreement of the Engineer, traces of zinc metal may remain occluded within the surface
of a blast cleaning profile after the removal of a zinc metal spray coating.
A13.12.7.5 Treatment at joints

a) Fasteners, joint material and parent metal in joints, before assembly or welding, in the shops or on site
(i) Fasteners (Bolts, nuts and washers)
Surfaces of uncoated fasteners shall be free from all traces of oil or grease before assembly.
Threaded fasteners at joints in galvanised steelwork, or galvanised steelwork which is to be painted, shall be galvanised.
Galvanised fasteners which are to be painted shall be etched before assembly.
Metal coatings on surfaces of fasteners which are to be painted shall be:
• free from all traces of oil or grease and then etched; or
• treated at the same time as the parent material where fasteners are already assembled.
Fasteners that have been etched shall be pressure-rinsed with water and allowed to dry before assembly or packing for delivery at
least one hour and not more than four hours after satisfactory application of an etch primer.
Fasteners that have become difficult to tighten because of corrosion shall be replaced.
(ii) Joint material and parent material in joints
The standard of initial blast cleaning of joint material and parent material in joints shall be at least equal to that for the parent
material. Before a joint is made on site, contact surfaces shall be restored to clean steel, SA 2½ or to sound metal coating.
(iii) Joints made with high strength friction grip and tension control bolts
In steelwork painted only overall:
The blast primer applied to the parent material shall be taken 10 mm to 15 mm inside the perimeter of the joints. The outer
surfaces and edges of site joint material may, at the option of the Contractor, also be given a coat of the blast primer.
In steelwork with thermally sprayed metal coating at joints only, and painted overall:
The thermally sprayed metal coating shall be applied to the contact surfaces of the joints and to the outer surfaces and edges of
joint material. The thermally sprayed metal coating on the contact surfaces of the parent material shall be taken 10 mm to 15 mm
outside the perimeter of the joints. The blast primer applied to the parent material shall be taken 10 mm to 15 mm inside the
perimeter of the joints. The thermally sprayed metal coating on the outer surfaces and edges of site joint material shall be given a
coat of aluminium epoxy sealer (2 packs).
In steelwork with thermally sprayed metal coating overall and sealed only or painted overall:
The thermally sprayed metal coating shall be applied to the contact surfaces of the joints and to the outer surfaces and edges of
joint material. The sealer applied to the parent material shall be taken 10 mm to 15 mm inside the perimeter of the joints. The
thermally sprayed metal coating on outer surfaces and edges of site joint material shall be given a coat of aluminium epoxy (2
pack) sealer.
In steelwork hot dip galvanized only or hot dip galvanized and painted overall:

All material at joints shall be hot dip galvanized. When an adhesion promoter and a first undercoat are applied before a joint is
made they shall be taken 10 mm to 15 mm inside the perimeter of the joint; these coats shall also be applied to edges and outer
surfaces of the joint material.
The thickness of a protective paint coat applied to the outer surfaces of joint material prior to assembly of any high strength friction
grip or tension control bolted joint shall not exceed 20 microns dry film thickness.
(iv) Non friction grip bolted joints
At shop joints in all steelwork other than in galvanised steelwork the blast primer alone or metal spray plus sealer shall be applied
initially to parent and joint material. Immediately before assembly of a joint which is to be painted the first undercoat shall be
applied to the contact surfaces and the joint made while the paint is wet.
At site joints in all steelwork other than in galvanised steelwork all surfaces except those of fasteners, shall receive in the shops
the shop protective system which is applied to the parent material.
At shop and site joints in galvanised steelwork an etch primer and shop coats may be applied to the joint material before or after
shop joints are made. When galvanised steelwork is painted on site etch primer and paint shall be applied to joint material after
the joint has been made.
(v) Welded Joints
At shop and site joints in all steelwork, surfaces to be welded shall be blast cleaned to SA 2½ or to bright steel and shall be free of
any protective or other coating.
b) Shop treatment of parent material adjacent to joints to be assembled or welded later on site
(i) At high strength friction grip and tension control bolted joints
The paint coats with the exception of the primer or first coat of paint, shall be stepped back at 30 mm intervals commencing 10
mm from the perimeter of the joints.
(ii) At non friction grip bolted joints
Shop paint coats are required to be stepped back.
(iii) Welded joints
Metal spray coating shall be separated from the weld by a distance of not less than 200 mm and a maximum of 300 mm from the
joint. The separation area shall be masked during metal spraying. Galvanising shall be removed a minimum of 10 mm back from
the edges of weld areas. Paint coats shall be stepped back at 30 mm intervals commencing at least 100 mm from the joint, or
from the edge of the metal spray.
(iv) Completed joints
Within 14 days of a joint being completed, exposed surfaces of parent and joint material shall be prepared as specified in the
undernoted Clauses.
(v) Bolted joints
Steelwork to be painted overall with blast cleaned or primed surfaces shall be prepared by dry blast cleaning to provide the
required standard of surface preparation.
Steelwork metal sprayed at joints only, and to be painted overall, primed or sealed metal sprayed coatings shall be prepared by
dry blast cleaning to the required standard.
Steelwork metal sprayed overall, and sealed only or painted overall, metal spray coatings shall be prepared in accordance with the
undernoted Clauses.
Steelwork galvanised or galvanised and painted overall, the surfaces shall be free from detrimental contamination.
(vi) At welded joints
In all steelwork welds shall be prepared by the methods and to the standards described for shop or site work as appropriate.
Surfaces of areas adjacent to the weld shall be similarly prepared. For site welds in galvanised steelwork, surfaces shall be
treated in accordance with the above Clauses.
(vii) Surfaces of fasteners
Uncoated and temporarily coated fasteners shall be free from all traces of oil and grease and blast cleaned to clean steel, SA 2½,
Medium profile, before painting.
Metal coated fasteners which have been etch primed before assembly shall be dry cleaned after final surface preparation of the
joint and then painted.
Fasteners which are to be metal sprayed after assembly shall be blast cleaned to clean steel, SA3, medium profile, with chilled
cast iron grit, cast steel grit or aluminium oxide.
(viii) Sealing of joints and plies
Bolted joints or built-up sections shall be free from any water which has penetrated the plies.
After drying out is complete and surfaces are dry after surface preparation, fine gaps around the perimeter of joints or along plies
shall be sealed by application of undercoat paint. All wider gaps shall be sealed with a sealant compatible with the paint system.
(ix) Sealing of gaps at nibs of load indicating fasteners or washers
Gaps shall be sealed by brush application of primer and successive undercoats, of the types used on adjacent areas

A13.12.7.6 Treatment at areas of mechanical damage/surface defects
Scores and indentations in the surface of a steel substrate or of a metal coating shall be treated by abrading or grinding to bright steel or bright
metal coating, to produce a surface without sharp edges or abrupt change in contour. Damage to unprepared surfaces shall be treated before
blast cleaning. A blast cleaning profile shall be restored on areas to be metal sprayed but not necessarily areas to be painted only. Other
surface defects in the steel substrate are subject to the approval of the Engineer.
In the case of damage to paint coatings only, surface preparation shall be by blast cleaning or abrading and the paint coatings restored.
When a two-pack epoxy paint system is restored over a steel substrate prepared by abrading, the adhesion of the first coat of paint to the
substrate shall be checked in accordance with EN 24624 or EN 22063 Annex A, method 1, before overcoating with the next coat in the system.
The first coat over abraded surfaces shall be an aluminium epoxy (2 Pack) primer.
Areas of metal spray to be repaired shall be dry blast cleaned immediately before further application of metal spray.
In the shops, a damaged metal spray coating, together with any damaged sealer or paint coats, shall be restored.
On site, with the exception of the small areas permitted above a damaged metal spray coating, together with any damaged sealer or paint coats
shall be repaired with a minimum thickness of 150 microns of metal spray.
On site, small areas of isolated damage in a metal spray coating plus paint system, need not be restored; after surface preparation the metal
spray shall be replaced by 100 microns of the first undercoats, omitting the sealer. Adjacent paint coats, excluding the sealer shall then be
restored over the repaired area.
In the shops, in the case of galvanising only, small isolated areas of up to 40 mm2 may, after surface preparation, be repaired with low melting
point zinc alloy.
Isolated areas of damage larger than 40mm 2 in galvanising which is to be painted later or which has already been painted may be repaired with
low melting point zinc alloy after surface preparation. Alternatively, the whole of the affected area including exposed steel substrate shall, after
surface preparation, be given a coat of adhesion promoter which, when wet cleaned in accordance with Clause A1312.7.2c) and finally dry, shall
be overcoated with two coats of Zinc Phosphate High Build Quick Drying Epoxy (2 pack) blast primer or Extended Cure Epoxy (2 pack) primer,
minimum dry film thickness of 75 microns each. The adhesion promoter shall not be applied over existing paints.
On site, surface of galvanised components found to have minor damage shall be prepared and coated with zinc rich primer of 100 microns mdft,
complying with BS 4652 Type 2 or 3. Alternatively, the components shall be regalvanised.
In all cases where paint coats only are to be repaired, or metal spray coats replaced or repaired, or galvanising is to be replaced by paint, the
edges of paint coatings or metal coatings adjacent to the affected area shall be bevelled back into sound paint or metal coating. This work shall
be carried out before any final blast cleaning described above.
Unless otherwise agreed by the Engineer, etch primer applied outside the agreed areas shall be removed immediately by wet cleaning.
In the shops exposure and overcoating times shall not exceed those specified in Clause A13.12.7.9.
On site, unless otherwise agreed by the Engineer, overcoating shall be started immediately after surface preparation of the affected area and
continued as soon as each coat is dry enough for overcoating.
Final coats shall be feathered into existing paintwork to ensure uniformity of appearance.
A13.12.7.7 Treatment of local failure in protective coatings

In the shops, failed paint coatings and failed metal spray coatings shall be restored. Abrading down to sound paint only, is permissible. If a
metal spray coating is damaged or reduced to less than 80% of the specified minimum thickness during abrading, it shall be restored.
On site, failed paint coatings and metal spray coatings shall be restored except that:
• abrading down to sound paint or to bright steel; or
• blast cleaning to clean steel, SA2½,
are permissible methods of surface preparation when restoring paint systems over a steel substrate.
In the shops, and on site unless otherwise agreed by the Engineer, galvanised components showing signs of failure of the coating shall be
regalvanised.
On site, in exceptional circumstances agreed by the Engineer, defective galvanising may be replaced by sealed aluminium metal spray of 100
microns minimum thickness in areas blast cleaned to clean steel, SA2½, medium profile using chilled cast iron grit abrasive. Blast cleaning and
aluminium metal spray shall taper off 50 mm into sound galvanising.
In the shops and on site, failed paint coatings over galvanising shall be restored. Unless otherwise agreed by the Engineer, surface preparation
shall be by abrading. Areas of sound galvanising exposed through a paint system shall be abraded only as necessary to ensure satisfactory
application of etch primer and paint. If the galvanising is damaged or reduced to less than 80 % of the specified minimum thickness during
abrading, the component shall be regalvanised.
In all cases of local failure, the extent of the failure and the required surface preparation, including extent of initial wet or dry cleaning down, shall
be agreed with the Engineer. Restoration of protective coatings shall not be started until the standard of surface preparation, including the
cleanliness of the surface, has been passed as satisfactory by the Engineer. Final coats shall be feathered into existing paintwork to ensure
uniformity of appearance.

A13.12.7.8 Metal coatings
a) Galvanised coatings
Galvanised coatings except for wire products shall comply with EN ISO 1461 and with the following:
• Inhibited hydrochloric acid with a strength not exceeding 14 % and within a temperature range of 15°C to 25°C or inhibited sulphuric acid
with a strength not exceeding 19 % and within a temperature range of 60°C to 80°C shall be used for pickling.
• Components shall not be immersed in the pickling acid longer than is necessary for cleaning the surfaces prior to galvanising.
• The surfaces of components to be galvanised shall be dried before immersion in the molten zinc.
• When an aqueous flux is to be used, all traces of acid shall be washed off immediately after pickling.
• Galvanised coatings shall be virtually free from imperfections, including porosity, to the satisfaction of the Engineer.
• Detrimental surface contamination of galvanised coatings which are to be painted shall be removed by wet cleaning in compliance with
Clause A13.12.7.2c). Surfaces to be painted shall not receive chromate passivation treatment.
• Vent holes drilled in hollow sections prior to galvanising shall be plugged to the satisfaction of the Engineer.
b) Sprayed metal coatings
Sprayed metal coatings shall comply with EN 22063 and with the following:
• Aluminium coating shall be of a material with minimum quality in accordance with type A1 99.5 (1050A) of ISO 209-1. Zinc coating shall
have a composition in accordance with type Zn 99.99 of ISO 752.
• The thickness of the coating shall be not less than 100 microns.
• The strength of adhesion of metal spray coatings shall not be less than the following:
Aluminium 50 kgf/cm2 Zinc 50 kgf/cm2
• Metal spray coatings shall be applied continuously over each 0,5 m2 per gun or the area of the component whichever is the lesser until
the specified thickness has been achieved.
• The application of thermally sprayed metal in separate layers will not be permitted.
• All surfaces to be metal sprayed, including that of the reference panel having equivalent hardness to that of the parent material, shall be
blast cleaned with chilled cast iron grit with a hardness value greater than 650HV, or aluminium oxide with a hardness value greater than
9 Mohs, and the standard shall be clean steel, SA3, medium profile.
c) Sherardized coatings
Sherardized coatings shall comply with Class 1, Table 1 of BS 4921 : 1988.
d) Electroplated coatings
Electroplated coatings shall comply with BS 3382: Part 2. Additionally, BS 3382: Part 2 shall be deemed to cover the electroplating of
components up to and including 36 mm in diameter. Electroplated surfaces which are to be painted shall not receive chromate passivation
treatment.
e) Other requirements
Before proceeding with the galvanising process the Contractor shall provide full details of the surface preparation and coating methods he
proposes to adopt and shall not put the work in hand until the Engineer's approval has been obtained. When instructed by the Engineer, similar
requirements shall apply in the case of other metal coatings.
When a metal coating is required on only part of a component it shall be applied before the rest of the component receives paint.
A13.12.7.9 Application of protective coatings

a) General
Paint shall be supplied from the Contractor's paint store to the painters ready for application. Any addition of solvent shall be made in the store in
the presence of the Engineer, and shall not exceed 5 % by volume on the paint.
Paint shall be applied only to surfaces which have been prepared and cleaned as described in this Series.
A coat of paint in a system shall be applied by one of the following methods:
• brush (B)
• airless spray (AS)
• air pressure spray
Paint shall not be applied under the following conditions:
• when the ambient temperature falls below 5°C or the relative humidity rises above 70 % in an enclosed workshop or 90 % on site;
• during rain, snow, fog, mist or in a dust laden atmosphere;
• when the amount of moisture likely to be deposited on the surface by condensation or rain before or after painting, may have a harmful
effect on the paint;

• when wind-borne dust may have a harmful effect on the paint.
All shop painting of steelwork shall be carried out in a fully enclosed workshop unless otherwise agreed by the Engineer.
Before starting the procedure trials described in Clause A13.12.8.3, and as required by the Engineer, the Contractor shall furnish the Engineer
with details of the overall wet film thickness for each coat he proposes to apply. He shall also provide information as to the total amount of paint
he expects to use for each coat of each system for which procedure trials are required. The calculation of the amount of paint to be used shall
be based on the volume solids plus an allowance for waste.
The following requirements on paint film thicknesses shall apply:
• Wet film thickness gauges shall be used where practicable to check that the wet film thickness is not less than:
• minimum dry film thickness (mdft) x 100/volume solids %
• During the application of a paint system the Contractor shall ensure that the progressive total thickness of the applied coats will allow the
specified minimum total dft of the system to be attained without exceeding, overall, the proposed wet film thicknesses referred to above
by more than 20 %.
• In no cases shall the total dry film thickness of a paint system or the mdft of the last undercoat and finish be less than that specified in
the Paint System Sheet.
• The local dry film thickness for any primer shall not exceed the specified mdft by more than 30 % and for other paints by more than 75
%.
Each coat of paint of a specified system shall have satisfactory adhesion as demonstrated by an adhesion test approved by the Engineer.
Each coat of paint of a specified system at whatever thickness applied shall be virtually free from surface defects, particularly cratering, pin-
holing, blistering, rivelling, sagging, bittiness, dry spray and cissing. The finished system shall be an even and uniform appearance. When
required by the Engineer, the finishing paint in visually sensitive areas shall be from the same batch.
When required by the Engineer, the degree of gloss of a finishing coat shall be agreed before the procedure trials. A painted tin plate reference
panel, 150 mm x 100 mm, shall be provided by the Contractor for this purpose.
All successive coats in a system including the stripe coats shall be in contrasting colours to aid identification.
Two pack chemically cured paints shall not be applied when the steel or ambient temperatures are below those advised by the paint
manufacturer, nor shall such paints be applied when the temperature is likely to fall below the advised temperatures during the curing period.
b) Stripe coats
Unless otherwise described in this section, two stripe coats shall be applied to all welds and all fasteners including washers and to all external
corners except those of rolled hollow sections. The first stripe coat, using second undercoat paint, shall be applied over the primer, sealer of
etch primer. The second stripe coat, using first or second undercoat paint, shall be applied before the last undercoat of the complete system in
the shops or on site as appropriate. The first stripe coat on etch primer fasteners shall be applied by brush; other stripe coats may be applied by
brush or airless spray as appropriate.
A solvent shall be used to remove final traces of grease from etch primer fasteners.
The Contractor shall enter the details of the stripe coats he has selected, giving the colour and method of application.
Square solid infill bars shall, after the second undercoat has been applied, be given an extra coat of first undercoat in lieu of stripe coats.
c) Exposure times for prepared steel surfaces and for metal coatings exposure times and treatment of etch primer and
overcoating times for paints
Clean steel prepared by dry blast cleaning or bright steel prepared by abrading or by grinding shall be primed within 4 hours.
Clean steel prepared by wet blasting cleaning only, shall be primed within 4 hours of being dry enough for painting.
Clean steel prepared by combined wet/dry blast cleaning shall be primed within 4 hours of dry blast cleaning.
Steel or steelwork blast primed at the mills or in the shops shall be overcoated within 8 weeks. The primed surfaces shall only be exposed
outside for a maximum of 2 weeks of the 8 week period. Prepared surfaces affected by detrimental contamination or corrosion which in the
opinion of the Engineer will reduce the required durability of the protective system shall be restored when directed by the Engineer.
Shop steelwork which has been metal sprayed shall be primed and sealed within 4 hours. The next coat shall be applied within 72 hours.
Shop prepared steel surfaces, unsealed metal spray coatings and undercoats, except final shop undercoat, shall not be exposed outside.
All etch primer surfaces, except those of fasteners which have been treated in compliance with Clause A13.12.7.5a)(i), shall, after initial drying,
be wet cleaned in compliance with Clause A13.12.7.2c), taking care not to remove adhering etch primer, and allowed to dry before overcoating.
The first coat of paint shall be applied within 48 hours of the etch primer surfaces being first dry enough for painting over.
Where galvanised steel is to be protected by a paint system etch primer shall be applied not later than 7 days after delivery to site unless
otherwise agreed by the Engineer.
A first shop undercoat shall be overcoated within 72 hours. Unless otherwise agreed with the Engineer, further shop coats shall be applied
within 72 hour intervals per coat.
The application of sealant in gaps may be carried out either before or after application, as appropriate, of the first coat of paint to be applied to
the completed joints or assembled plies.
Prepared steel surfaces and sprayed metal coatings which have been restored, also paint coats and galvanising which have been prepared after
surface damage or deterioration shall be overcoated with the sealer primer or first undercoat as appropriate before the surfaces have been
affected by moisture and in any case within 4 hours.

On site, steel surfaces and metal spray coatings shall be primed or sealed within 4 hours and shall have the following coat applied within 72
hours unless otherwise agreed with the Engineer. The next coat shall be applied within a further 72 hours unless otherwise agreed with the
Engineer.
A13.12.7.10 Storage and transport of steel and fabricated steelwork

Steel awaiting fabrication for the Permanent Works and uncoated steelwork shall be adequately protected from contaminants liable to cause
heavy rusting and possibly pitting of the surfaces.
Steelwork shall not be loaded for transport until the paint system is sufficiently hard for handling.
During storage, steelwork shall be kept clear of the ground and shall be laid out or stacked so as to prevent water or dirt accumulating on or
against any of the surfaces. Suitable packings shall be placed between layers of stacked steelwork. When cover is provided it shall be
ventilated sufficiently to keep condensation to a minimum.
Components weighing less than one tonne shall be kept in a storage area away from their erection point in order to minimise damage to
protective coatings.
Lengths of parapet and individual lighting columns shall be supported on timber, and precautions taken to prevent damage to their protective
coatings and ingress of water. They shall only be positioned adjacent to their erection point immediately before erection. If the planned erection
time is delayed by more than 72 hours the components shall be returned to the storage area.
If in the opinion of the Engineer, damage to coatings is excessive, or may be difficult to deal with satisfactorily after erection, the Contractor shall
restore the coatings before erection.
A13.12.7.11 Surfaces in contact with concrete

Metal spray coatings and all shop paint coats shall be returned 25 mm into the concrete/steelwork contact area.
Where aluminium metal spray, which has been sealed only, is returned into the contact area, it shall be given a coat of Phosphate Epoxy Ester
Undercoat of 40 microns mdft, not later than 48 hours before concreting. Application of the paint outside the contact area shall be prevented, by
masking if necessary.
Galvanised coatings shall be applied overall and may come into contact with concrete.
A13.12.7.12 Access and lighting

Without prejudice to the Conditions of Contract, access for inspection by the Engineer shall be provided and erected by the Contractor. The
access shall be agreed with the Engineer as being adequate and safe in all respects for inspection purposes.
Manual surface preparation and coating application work shall not be carried out when light intensity at the workface is less than 500 lux. When
the natural light intensity falls below this level the Contractor shall install and maintain temporary lighting which shall provide a minimum light
intensity of 500 lux over at least 1,0 m2 at the workface during the work and also for inspection when required by the Engineer.
A13.12.7.13 Additional requirements for the protection of steel in bridge bearings

Work described in this Clause shall be carried out in compliance with the foregoing Clauses, as appropriate.
All external surfaces of the bearings shall be given full protective treatment. When seeking approval of a particular bearing manufacturer the
Contractor shall provide full details of the protective treatment of the proposed bearing. This shall include the proposed treatment of all metal
surfaces within the bearing and all screwed or other fastenings Information, including the name of the paint manufacturer, required for
completing the Paint System Sheet, for the bearings, shall be obtained by the Contractor from the bearing manufacturer.
Etch primer and MIO Epoxy paints when required for application on site shall be obtained from the manufacturer of the shop applied coats.
Paint applied to the bearings on site to match the bridge steelwork paint system shall be obtained from the manufacturer of that system.
A13.12.7.14 Powder coating

Aluminium sheeting and sections shall be powder coated in accordance with SANS 1796 – Coatings of durable organic powder for external
architectural aluminium. Powder coating used shall be of the ‘Super Durable’ type and comply with SANS 1578 – Durable organic powder for
coating of external architectural aluminium.
The powder coating shall have a 25 year life in the service environment and this shall be guaranteed in writing by the powder coating supplier
and powder coating applicator. An insurance backed guarantee shall be offered to the Client.
A SANS 1578 certified mark holder only shall apply the powder. The applicator must show in writing approval from the powder manufacturer for
the pre-treatment process and powder application process to be used.
Unless otherwise advised by the powder manufacturer the thickness of the applied and cured powder coating shall be at least 80 microns. All
powder coated sheeting shall be totally free of pinholes. Colour and gloss shall be uniform on all sheeting.
The powder coating shall be nominally semi-gloss, the actual gloss level and colour shall be agreed with and approved by the Engineer before
any powder coating is manufactured.
Powder coating supplier and applicator shall have a quality system in accordance with ISO 9001.
Documentation in support of the Guarantee shall be accordance with Association of Architectural Aluminium Manufacturers of South Africa
(AAAMSA) recommendations as a minimum.
Once powder coating and inspection is completed all approved coated sheeting shall be protected adequately using bubble wrap or polythene
adhesive film to minimise damage during transportation, storage and during and after installation.
Powder coated sheeting shall be stored in accordance with the powder coating manufacturer’s recommendations. Any situation that might result
in water marking of the powder coating shall be avoided.

Damaged powder coating shall be repaired strictly in accordance with the powder manufacturer’s recommendations and Guarantee
requirements. The Engineer shall decide if any damaged sheet is to be replaced rather than repaired.
The powder manufacturer shall advise the Engineer what, if any, cleaning and maintenance procedures are required to ensure the Guarantee
once sheeting is installed. This information shall be supplied before any powder coating commences.
A13.12.7.15 Specified paint systems

a) General
The undernoted systems shall be applied to the specified surface areas.
Subject to the approval of the Engineer, alternative systems may be proposed by the Contractor, provided that they can be demonstrated to
have equivalent durability.
The top coat shall be applied either at site or in the shop. The Contractor shall ensure that the final appearance of painted steelwork is uniform.
The paint systems for external systems below include provision for an aesthetic paint layer. This paint layer is not considered part of the system
for durability but is to be applied to ensure uniform appearance of exterior steel surfaces. At the discretion of the Engineer this layer may be
omitted if the system top coat after completion of painting to all areas gives a satisfactory appearance.
Where quoted item numbers relate to the UK Highways Agency Design Note BD 35.
b) System 1:
Durability – major maintenance: 25-30 years
Surface Preparation - Blast clean to BS 7079 or EN ISO 11126 Sa 3 Medium Profile
Shop - Aluminium metal spray - 100 microns mdft
Shop - 1st coat Item 159 Aluminium Epoxy Sealer - applied at 12 to 20 sq.m/litre
Shop - 2nd coat Item 111 Zinc Phosphate HB QD Epoxy Blast Primer - mdft 100 microns
Shop - 3rd coat Item 112 MIO HB QD Epoxy undercoat/finish- mdft 125 microns
Shop/Site - 4th coat Item 169, semi-gloss, Acrylic Polyurethane (2 pack) finish - mdft 50 microns, colour as given in the specifications or on the
drawings.
Stripe coat - 3rd coat on 2nd coat by brush at 75 microns mdft
Minimum system total dry film thickness - 425 microns including metal spray
Minimum total dry film thickness of paint system - 300 microns
Aesthetic top coat - Item 169, semi-gloss, Acrylic Polyurethane (2 pack) finish - mdft 50 microns, colour as given in the specifications or on the
drawings.
HSFG joints – contact faces aluminium metal spray only; fasteners - aluminium metal spray after joint is made. Complete with system as above.
c) System 2:
Durability – major maintenance: 20-25 years
Surface Preparation - Blast clean to BS 7079 or EN ISO 11126 Sa 3 Medium Profile
Shop – 1st coat zinc rich epoxy primer to 50-75 microns dft
Shop – 2nd coat epoxy MIO undercoat to 100 microns mdft
Shop – 3rd coat epoxy MIO undercoat to 100 microns mdft
Shop/Site – 4th coat item 169, semi-gloss, acrylic polyurethane (2 pack) finish - dft 50 microns, colour as given in the specifications or on the
drawings.
Stripe coat 3rd coat over 2nd coat
Minimum total dry film thickness 325 microns
Aesthetic top coat - Item 169, semi-gloss, Acrylic Polyurethane (2 pack) finish - mdft 50 microns, colour as given in the specifications or on the
drawings.
d) System 3:
Durability – major maintenance: 25 years
Surface Preparation - Blast clean to BS 7079 or EN ISO 11126 Sa 21/2 Medium Profile
Shop – 1st coat Item 111 Zinc Phosphate HB QD Epoxy Blast Primer - mdft 125 microns
Shop – 2nd coat Item 112 MIO HB QD Epoxy undercoat/finish- mdft 100 microns
Stripe coat 2nd over 1st
Minimum total dry film thickness 250 microns

e) System 4:
Durability – major maintenance: 25 years
Surface preparation - Galvanize in accordance with EN ISO 14713/EN ISO 1461, degrease with a water emulsifyable degreaser and wash with
fresh water, allow to dry. Sweep blast in accordance with EN ISO 12944 with a fine grade of non-metallic grit, such as garnet, at low air pressure
taking care only to roughen and not remove the zinc coating.
1st coat – Epoxy MIO (formulated for application to galvanized steel) - mdft 75 microns
2nd coat – Epoxy MIO (formulated for application to galvanized steel) - mdft 75 microns
3rd coat – Acrylic polyurethane - dft 50 microns
Stripe coat 2nd over 1st
Minimum total dry film thickness 175 microns and a maximum of 300 microns
f) System 5:
Aluminium sheeting and sections to be powder coated in accordance with Clause A13.12.7.14, colour as given in the specifications or on the
drawings.
A13.12.7.16 Safety of painting operation

Some paints and preparation processes are harmful, including being flammable, carcinogenic and containing volatiles harmful to a person.
The supplier’s instructions regarding health and safety shall be strictly adhered to. This includes storage, handling, protective equipment, breathing
apparatus and masks.
Appropriate protective clothing and breathing apparatus shall be worn during preparation of surfaces to be painted.
A13.12.8.1 Testing of metal spray coatings
At the start of the Works, and later at intervals specified by the Engineer (with the exception of coatings on steel in bearings, curved surfaces,
repairs to mechanical damage, local failure of metal spray at site joints or areas restored on site), the Contractor shall demonstrate by means of
a pull off test, of a type approved by the Engineer, that the minimum adhesion requirement is being attained. In the excepted areas the
Contractor shall demonstrate to the satisfaction of the Engineer that the adhesion is satisfactory when tested in accordance with EN 22063.
Areas affected by the tests shall be restored.
The pull off tests shall be carried out initially on panels 150 mm x 150 mm x 6,0 mm which are of the same grade of steel as the parent material
and which before blast cleaning had the same surface condition. The panels shall be blast cleaned and metal sprayed together with the parent
material to the same standard and using the same technique.
The Contractor shall make arrangements for the Engineer to witness the preparation of the panels and all testing. When instructed by the
Engineer, the Contractor shall carry out further tests on similarly prepared and metal sprayed panels.
If the adhesion requirement on any test panel is not met, the Contractor shall carry out a further test on the parent material adjacent to the panel
position. In the case of adhesion failure on the steelwork itself by either method of test, unsound metal spray coating shall be restored and the
tests repeated.
If more than two local areas of faulty adhesion occur on any one component, the whole of the metal spray coating on the component shall be
considered as having failed, and it shall be restored. Clause A13.12.7.4c) is not applicable in the case of adhesion failure.
A13.12.8.2 Testing of paints

a) Provision of samples
The Contractor shall provide unopened 5 litre samples, known as 'A' samples, for quality assurance purposes, of each type of paint to be used
for the Permanent Works. In addition, the Contractor shall supply 500 ml samples, known as 'B' samples, for application control purposes.
b) ‘A’ samples
'A' samples are required in all cases where more than 500 litres of any one coat of paint is to be applied. For 2 pack systems separate samples
of the base and activator are required.
The first 'A' samples shall be taken from the first batch of each type of paint delivered to the fabricator's shop or to site and accepted by the
Engineer as being representative of paint to be used for the Works. First batches of paint of less than 200 litres shall be discarded as not being
representative and shall not be used in the Permanent Works.
Additional 'A' samples of the paints shall be provided by the Contractor depending on the weight of structural steelwork in the Permanent Works
in accordance with the following:
• 250 tonnes to 500 tonnes : one set of samples;
• over 500 tonnes : a further set of samples for each part of or whole 500 tonnes.
When the Contractor instructed by the Engineer shall also provide an 'A' sample:
• of any replacement batch of paint subject to testing as above;
• returned paint described under Clause A13.12.5.2;
• when the paint, in the opinion of the Engineer, is showing unsatisfactory application characteristics under Clause A13.12.7.9.
Immediately after selection by the Engineer, the 'A' samples shall be despatched by the Contractor to the testing authority in accordance with the
Engineer's instructions.
Paint shall be supplied in sufficient time to allow for sampling and testing before the start of application.
Unless permitted by the Engineer, painting, except for procedure trials, shall not start until the Engineer confirms that the first 'A' samples are
satisfactory.
c) 'B' samples
The Contractor shall take 'B' samples when instructed by the Engineer, and only under his supervision. The samples shall be taken from
painters' kettles or from nozzles of airless spray guns directly into clean, new 500ml tins which shall be filled and then sealed and handed to the
Engineer. On return of the samples to the Contractor, the Contractor shall despatch them immediately to the testing authority in accordance with
the Engineer's instructions.
d) Provision of 500ml tins, packing and transport of 'A' and 'B' samples
The Contractor shall provide 500 ml tins with lids and lid clips, for 'B' samples at the start of painting or before any procedure trials required by
Clause A13.12.8.3. The quantity supplied shall be sufficient to avoid any delay in taking 'B' samples throughout the work.
The Contractor shall ensure that the lids of all tins of sample paint are securely clipped down when they are despatched for testing.
The Contractor shall be responsible for handling, packing as necessary, prompt despatch and transit of 'A' and 'B' samples.
A13.12.8.3 Procedure trials

The Contractor shall carry out to the approval of the Engineer shop and site procedure trials of the protective system when more than 50 litres of
any coat of paint are to be applied to the steelwork.
Procedure trials are not required for systems applied to joints or for galvanising only. The procedure trials shall be completed at least ten days
before the start of application of the systems on the main steelwork. The trials shall be carried out with the labour and equipment to be used for
the work.
The Contractor shall provide for the shop trials, samples of steel from 2,0 m2 to 10 m2 representing the main steelwork, galvanised when
necessary, as required by the Engineer. The Contractor shall demonstrate his ability to carry out surface preparation by blast cleaning and by
using power assisted tools, to apply metal spray coatings and the paints he has selected. He shall provide sufficient paint for the trials.
Metal spray application and painting of the main steelwork shall not be started in the shops or on site until procedure trials have been completed
to the satisfaction of the Engineer.
Any adjustment to the registered paint formulations shown to be required by the trials, other than an adjustment to the solvent shall be agreed
with the Engineer and made at the paint manufacturer's works.
Unless otherwise agreed by the Engineer the Contractor shall carry out further procedure trials whenever he employs replacement skilled labour
or proposes to use equipment of a different type.
A13.12.8.4 Paint system data sheet

A minimum of 56 days prior to first application of protective coatings the Contractor shall submit for approval a copy of the Paint System Data
Sheets.
A sample Paint System Data Sheet is shown on the following page.
The Contractor shall submit details of other structures on which the proposed paint system has been applied, and in particular details of its
durability.
The Contractor shall submit copies of the manufacturer’s instruction for application of the proposed paint system.

PAINT SYSTEM SHEET Sheet No.
1. CONTRACT TITLE: STRUCT. NO.: GRID REF: 2. DATE OF ISSUE OF DOCUMENTS

TO TENDERERS:
3. ENVIRONMENT AND ACCESSIBILITY: 4. REQUIRED DURABILITY OF SYSTEM

NO MAINTENANCE :
5. PAINT SYSTEM TO BE APPLIED OVER: MINOR MAINTENANCE:

MAJOR MAINTENANCE:
6. DETAILS 1st Coat 2nd Coat 3rd Coat 4th Coat 5th Coat 6th Coat
Registered Description
Item No. & Colour
Date Registered
Brand Name and Manftr's Ref No.
Data Sheet No.

Where applied
How applied
Min dry film thickness (mdft)

Max local dft (See Cl. I1015(a))
7. STRIPE COAT DESCRIPTION (including Item No and Colour) 8. PAINT MANUFACTURER'S OFFICIAL
STAMP:
Shop:
Site:
9. MINIMUM TOTAL DRY FILM THICKNESS OF PAINT SYSTEM (See Note) 10. APPROVED BY:
NOTE: The calculated sum of the mdft, neglecting the thickness of primers under 25 microns applied to blast cleaned steel, sealed or unsealed DATE:
aluminium metal spray, shall not be less than 84% of the minimum total dry film thickness of the paint system

B13.12 STRUCTURAL STEEL PROTECTIVE TREATMENT OF MAJOR
STRUCTURES
CONTENTS
B13.12.1 SCOPE
B13.12.3 GENERAL
B13.12.5 MATERIALS
B13.12.1 SCOPE
This Section covers the protective treatment of structural steelwork for major steel structures, e g steel bridge decks, composite steel decks, and
steel and composite steel cable-stay towers. It does not apply to protective treatment of minor steel structures such as sign gantries, which is
covered in Section A13.10. Due to the specialised application and skill levels, Part A is not suitable for labour enhanced work.
B13.12.3 GENERAL

B13.12.5 MATERIALS



C13.12 STRUCTURAL STEEL PROTECTIVE TREATMENT OF MAJOR
STRUCTURES
(i) Preamble
None.
pay items.
C13.12.1 Steelwork protective system:
C13.12.1.1 (system and location to be specified) square metre (m2)
C13.12.1.2 (system and location to be specified) square metre (m2)

The unit of measurement shall be the calculated square area of steelwork to be protected. The item shall be measured once and shall include all
shop and site coats specified to generate the itemised paint system.
The tendered rate shall include full compensation for the following:
(a) dispatching paint samples to testing authority;
(b) shop procedural trials;
(c) site procedural trials;
(d) compilation and where necessary re-compilation of painting programmes;
(e) masking and other measures to protect adjacent untreated work and the removal of masking and other measures upon completion;
(f) grounding down welds and removal of weld splatter;
(g) joint fillers and treatments of joints;
(h) curing agents;
(i) preparing materials for application
(j) preparation of surfaces and coating at the place of fabrication and on site including blast cleaning, solvents, detergents and where
approved by the Engineer, acid washing;
(k) re-preparation where steelwork or coatings have become contaminated;
(l) complying with any special requirements in respect of ambient conditions including the containment of dust and debris and for intervals
between successive operations and applications;
(m) labelling;
(n) storage;
(o) stripe coats;
(p) de-nibbing;
(q) heat treatment;
(r) obtaining the correct dry film thickness of paint or other coating and forwarding results to the Engineer;
(s) measures to protect uncoated steelwork;
(t) preparation and supply of system and data sheets;
(u) facilities, including lighting and access, and assistance to enable inspection by the Engineer;

D13.12 STRUCTURAL STEEL PROTECTIVE TREATMENT OF MAJOR
STRUCTURES
CONTENTS
D13.12.1 SCOPE
D13.12.2 GENERAL
D13.12.1 SCOPE
D13.12.2 GENERAL
Paint and similar protective coatings: each type and batch: Refer to the “Paint System Sheet”.

a) No additional requirements.

Performance testing shall be carried out on the following coatings in accordance with the specifications:
(a) Metal spray coatings; and
(b) Paint.

13.13 INCREMENTAL LAUNCHING OF BRIDGE DECKS
CONTENTS
A13.13.1 SCOPE
A13.13.3 GENERAL
A13.13.5 MATERIALS

A13.13 INCREMENTAL LAUNCHING OF BRIDGE DECKS

A13.13.1 SCOPE
This Section covers the requirements for the incremental launching method of construction for bridge decks, and includes temporary work (i.e.
all works temporary in nature and required for construction of the permanent works), launching of the deck segments and the permanent work
not covered elsewhere in the Standard Specifications.
A13.13.3 GENERAL
A13.13.3.1 Method Statement and Procedural Manual
A detailed ‘Method Statement and Procedural Manual’ for the construction and launching of the deck shall be prepared and submitted to the
Engineer at least 56 calendar days before first segment is launched, for consideration and approval. It shall include, inter alia, a detailed
programme, details of the equipment and devices to be used including casting yard and launching anchors, anticipated maximum launching,
restraining and pull-back forces, launching girder design, details of the method to be used in measuring pier deflections, control measures,
monitoring systems and proposed emergency procedures.
A13.13.3.2 Superintendence
The Contractor’s representative shall be an ECSA registered Professional Engineer or Technologist, who is conversant with all aspects of the
incremental launching method of construction, in attendance for the full duration of construction up to completion of the expansion joint
installation.
An experienced surveyor, using precision survey equipment, shall be responsible for the setting out, level control of the temporary and
permanent work, and for controlling the launching alignment.
A13.13.3.3 Temporary work

Temporary work shall include all those elements of construction which are not permanently incorporated into the structure when completed, and
shall include the casting yard, launching girder, fasteners and elements embedded in the permanent works to accommodate the temporary work.
On completion of the construction, the temporary works shall be removed and the permanent work repaired to the satisfaction of the Engineer.
Where agreed to by the Engineer, parts of the temporary works need not be removed. Details of the temporary work shall be submitted to the
Engineer at least 56 calendar days before first segment is launched.
A13.13.3.4 Design
Details of the temporary work and, if required, supporting calculations, shall be submitted to the Engineer for consideration. Approval or
acceptance given by the Engineer for such designs and drawings will be subject to the provisions of Clause A1.2.4 of Chapter 1 of the Standard
Specifications.

The Contractor shall accept full responsibility for the designs so prepared and shall include any modifications to the permanent work. Design
work shall be certified by an ECSA Registered Professional Engineer.
A13.13.3.5 Design variations

In addition to the temporary work drawings, written descriptions highlighting variations from the contract drawings shall be submitted to the
Engineer.
The incorporation of variations to the works occasioned by the Contractor’s temporary work including a change in weight, stiffness and geometry
of the launching girder, proposed pre-stressing system, method of installation of permanent bearings, launching equipment, launching method,
or any proposed deviations from the original construction procedure, shall be subject to the approval of the Engineer.
Additional work and materials giving rise to extra cost (including any additional redesign costs of the permanent structure) as a result of design
variations shall be for the Contractor’s account and expense. The additional cost resulting from the variations shall be deemed to be included in
the contract rates and sums. Measurement will be based on the contract drawings and payment will be based on the tendered rates and sums.
A13.13.3.6 Programme
A programme for construction and launching of the deck, detailing the proposed construction cycle and the daily activities, the time and
sequence in which the concrete shall be placed and pre-stressed, and the curing period and method of curing to be used, shall be submitted to
the Engineer at least 56 days prior to commencement of the launched bridge construction.
A13.13.5 MATERIALS
The relevant Clauses of relevant Chapters of the Specifications shall be binding unless otherwise specified in this Section.

A13.13.6.1 General
The equipment shall include the jacks, mechanisms, devices and accessories necessary for the operation of the particular system for the
launching of the bridge deck, for the girder lifting system, for installation of the bearings, for pulling back of a segment, for the emergency
facilities and for anchoring, locking and braking of the deck. Full details of the equipment and devices shall be submitted to the Engineer.
Provision for fixing the equipment to the permanent work shall be made by casting the necessary sheaths, bars, anchors, etc. into the concrete.
A13.13.6.2 Jacking and measuring equipment

The jacking equipment shall be supplied with new hoses and connections which shall be operated, and where necessary replaced, in
accordance with the manufacturer’s instructions. All hydraulic hoses and connections shall be capable of withstanding 150 % of the rated load
capacity. Calibration certificates, no older than one year, of all jacks used shall be provided to the Engineer.
The lifting jacks used for adjustments to the temporary bearings or for installation of permanent bearings, shall have self-levelling spherical
heads and shall provide for adjustment to within 1mm of the required level. All the jacks used at a particular support shall be of the same model
and shall be hydraulically linked to the same pressure source.
The launching and lifting jacks shall be equipped with mechanical locking devices to secure the deck in position.
The jacking system for launching the deck shall incorporate a control device which will automatically prevent the maximum jacking force, from
being exceeded.
The launching equipment shall be designed to ensure that a power failure will not lead to uncontrolled movement of the deck.
A13.13.6.3 Design
Sufficient jacking or restraining force for launching of the bridge deck shall be provided to overcome the most adverse combination of forces
arising from the frictional forces at the temporary bearings, the sliding resistance of the deck in the deck construction area, and the forces
associated with the gradient of the bridge deck, taking construction inaccuracies into account.
The launching, restraining or pull-back forces shall act directly on the deck through fail-safe mechanical means and shall not rely on friction.
The restraining capacity to be provided, shall have a factor of safety of 1,3 against uncontrolled sliding.
For design of the restraining or braking mechanism, the sliding friction coefficient shall be assumed to be zero.
A13.13.6.4 Emergency facilities

An automatic emergency switch system, capable of immediately stopping the launching procedure, shall be installed at the top of each pier. This
system must be activated automatically when the calculated pier deflection as given on the drawings, is exceeded.
Deflections at the top of the piers may be monitored utilising a high tensile steel wire stretched along the centre line of the bridge. The wire must
be stressed sufficiently to negate the effect of temperature variation on the deflection measurements and equipped with a scale at each pier that
will permit the direct reading of the deflection to an accuracy of 1,0 mm. It should be supported on low friction rollers at each pier. Details of this
or any other proposed method of measuring the deflections shall be submitted to the Engineer for approval.
Provision shall be made at the top of the piers for the installation of emergency jacks under the webs which may be required to lift the deck in
order to remove temporary bearings or launching pads or to effect adjustment of the temporary bearings. If insufficient space is available on top

of the piers, provision shall be made for the installation of brackets at the pier head to support the jacks. Alternatively, temporary deck
diaphragms that will permit jacking under the soffit slab shall be provided.

A13.13.7.1 Deck construction area
a) General
The work required for establishing the deck construction area comprises inter alia: the treatment or substitution of the in situ material and
construction of the earthworks; the design and construction of the foundations, structures and other temporary work to facilitate construction of
the deck including temporary supports, jacking buttresses and anchors; modifications to the permanent work; and the provision of drainage to
the area.
At least two control survey beacons shall be established in close proximity to the construction area and shall be suitably protected. The position
and level of each beacon shall be established to within an accuracy of 1,0 mm and shall be monitored at intervals to be agreed with the
Engineer.
The deck construction area shall be located at the end of the bridge as shown on the drawings or proposed by the contact.
Temporary concrete work in the construction area need not be demolished except for members, which in the opinion of the Engineer, could
impede free drainage, interfere with the permanent work or detract from the appearance of the finished works.
Any modification of the abutment to suit the launching equipment and for pulling back of the deck shall be subject to the Engineer’s approval.
b) Foundations
Foundations within the deck construction area shall be stable and not settle more than 10 mm during the course of construction. If settlement of
more than 10 mm is anticipated, the spine beams and the support for the formwork assembly shall be constructed on piles or other suitable
structures, with provision to compensate for elastic deformations. A geotechnical appraisal report is required in this regard confirming founding
conditions and expected settlements.
c) Cover to casting area
The deck casting area shall be protected from the elements by means of a sturdy, mobile, covered structure of sufficient size to prevent rain,
wind and direct sunlight from reaching the casting area, and to enable work to progress during inclement weather. The covering shall ensure
that the launching cycle is maintained and shall prevent delays that result in extension of time of the construction of the bridge. The covering
shall consist of durable material which is adequately secured and maintained during the construction period.
A13.13.7.2 Formwork assembly

a) General
The formwork assembly comprises the complete internal and external falsework and formwork including the access ladders and platforms, the
spine beams and sliding surfaces and the jacks and devices required for aligning and operating the assembly. The complete assembly shall be
constructed on the foundation prepared in the deck construction area.
b) Design
The spine beams shall not deflect more than 2,0 mm during construction of the deck nor shall the differential deflection between spine beams at
any deck cross section exceed 2,0 mm.
The factor of safety for the formwork assembly against overturning at the serviceability limit state just before the launching nose reaches the next
support shall be at least 1.20.
c) Construction
With the exception of the sliding surface on the spine beams, the formwork assembly shall allow for the contact between the external formwork
and the concrete to be broken before the launching process takes place. It shall also provide for the independent adjustment of the spine beams
from the deck formwork, and shall incorporate hydraulic or mechanical devices which will permit adjustment of the assembly to compensate for
any settlement as referred to in Clause A13.13.7.1b). Any hydraulic equipment utilised, shall be equipped with mechanical locking devices which
shall prevent movement during the placing of the concrete and launching.
The formwork assembly shall be sufficiently rigid and the spine beams firmly founded to ensure that the superstructure can be built within the
specified tolerances.
The top of the spine beams shall be horizontal in the transverse direction unless shown otherwise on the drawings.
Welded joints on the sliding surfaces shall be ground flush with the adjoining parent material.
The formwork unit shall allow for any extra length of a segment which may be needed to compensate for the effects of elastic shortening,
shrinkage and creep of the deck occurring during the course of construction.
The internal formwork for the deck section shall be adjustable, or shall consist of independent sets, which can be adapted to the variations on
the inside of the deck section. For the subsequent construction of the diaphragms at the supports, the formwork for the webs shall accommodate
splice bars or embedded couplers as shown on the drawings.
All formwork shall be steel. Any formwork panel that is damaged during launching shall be replaced before the next segment is prepared for
construction. The shutter release agent and curing compound shall not stain the concrete.
The section of horizontal formwork which forms the sliding surface shall be located under the webs of the deck section and rest on the spine
beams. The curvature of this formwork shall be the same as that of the bridge deck and the front shall be tangential to the back of the preceding
deck segment. ‘Marineply’, at least 25 mm thick or an equivalent material shall be used and the contact surface between the formwork and the
spine beams shall be treated with an approved lubricant to facilitate sliding from the deck construction area.
The ‘Marineply’ or equivalent material shall have no surface defects and shall be joined only in the transverse direction at agreed fixed intervals.
The material shall be replaced when the surface or the edges are damaged and a surface finish equivalent to F3 can no longer be achieved.
After this formwork has been retrieved, it shall be cleaned and inspected for damage before reuse.
A13.13.7.3 Launching girder

a) Design
Details of the postulated launching girder geometry, weight and stiffness are indicated on the drawings. The Contractor shall use these details
when designing the launching girder or may prefer to modify the specified details. Any modifications required to the postulated girder resulting in
a redesign of the deck, shall be considered in accordance with the General Conditions of Contract: “Alternative Designs and Offers” and must
take into account any design parameters given on the drawings and in the specifications. Increasing the weight of the launching girder above
the postulated weight is also considered as an alternative design and the Contractor shall bear all additional costs including design, design
checking, additional prestress, additional concrete and additional steel to the launching girder.
Shop drawings together with supporting calculations shall be submitted to the Engineer for consideration before commencing with the
fabrication. It should be noted that any variation by the Contractor from the information given on the drawings may require redesign of the
permanent work which is affected by the temporary works. Any additional construction costs incurred in the permanent works as a result of the
Contractor’s temporary works shall be to the Contractor’s account.
The design of the girder shall conform to the requirements of the latest revision of BS5400: Part 3 ‘Code of practice for the design of steel
bridges’. An alternative recognised design code may, however, be proposed for consideration. Acceptance of an alternative design code shall
not relieve the Contractor of his responsibility to provide a safe launching girder.
The design shall also include details of the connection of the girder to the leading deck segment and any modifications to the segment. The
anchorage system for the connection shall be arranged symmetrically around the vertical axis of the main girder and must be sufficient to
prevent separation of the girder from the deck during launching.
The structural stiffness of the launching girder has a determining influence on the design of the bridge deck and the Contractor shall therefore
allow full compensation in the rates and amounts for all extra costs for re-design and re-detailing associated with alternative launching girders.
The launching girder shall be designed such that it can be readily re-assembled during commencement and dismantled after completion of the
launching.
Once the first two segments of the deck have been launched, the launching girder may not be used to steer the deck or move the deck
sideways. All steering and lateral jacking shall take place on the bridge deck.
Where the bridge deck soffit is located on a vertical or horizontal curve, the postulated launching girder may follow the curvature of the deck
soffit in a series of short chords, within the capability of the sliding pad width/bearings. The forces induced in the deck by the launching girder
not following the curvature of the deck, shall not increase the deck design forces.
b) Fabrication
Radiographic examinations of all flange joints and at least 30 % of the total length of web and web/flange joints, shall be undertaken after
fabrication of the launching girder. This requirement shall also apply to any alternative launching girder used previously on other contracts.
A certificate from an independent inspection authority certifying that the welding and fabrication of the launching girder complies in all respects
with the design shall be submitted to the Engineer.
The front of the launching girder shall be fitted with a hydraulic lifting device capable of lifting the deflected girder onto the launching bearings at
each temporary support.
A13.13.7.4 Temporary bearings, guides and pads

a) Temporary bearings and guides
(i) Design and fabrication
The anticipated loads on the temporary bearings are given on the drawings.
Side guides shall be provided on both sides of the deck at each support to safely control the alignment of the deck during
launching. They must be designed to withstand the horizontal loads due to wind or earthquake during construction, as well as any
construction inaccuracies or steering that may be required, and may be incorporated into the design of the temporary bearings.
The stainless steel sliding surface to the temporary bearings shall comply with the requirements of Clause A13.6.5.1d) and show
no deviations exceeding 0,2 mm between two points. The entry and exit slopes shall be suitably radiused.
Temporary bearings shall be designed to permit replacement and adjustment during the course of construction if so required.
(ii) Installation and adjustment
The temporary bearings shall be installed with their centrelines coincident with the centrelines of each main web of the launching
girder or as shown on the drawings. In the longitudinal direction, the slope of the sliding surface shall be tangential to the arc (if
any) on which the deck is located at that point. In the transverse direction the bearings shall be horizontal unless the deck is
launched on an inclined circle in which case the transverse slope is determined by the plane of the inclined circle.
The installation shall allow for the replacement of the bearings or for periodic adjustment of the level of the bearings as
contemplated in Clause A13.13.7.8b).
When adjustment or replacement of a temporary bearing is required, the deck or the launching girder shall be lifted as specified in
Clause A13.13.7.8i), subject to the provisions of Clause A13.13.6.2, and the bearing adjusted or installed to the prescribed level.
Lifting of the deck may take place at one support only, at any one time.
The bedding of the temporary bearings shall be capable of transmitting the imposed load safely into the substructure.

(iii) Tolerances
Unless otherwise indicated on the drawings, the temporary bearings shall, in addition to the installation requirements indicated in
Clauses A13.13.7.4a)(i) and A13.13.7.4a)(ii) above, be installed within all the following tolerances:
• Bearings be placed within 5,0 mm of their calculated theoretical value;
• The cumulative error between adjacent bearings on the same support, measured from a plane parallel to the deck soffit,
should not exceed 2,0 mm; and that
• The cumulative error, measured from a plane parallel to the deck soffits, between any two points on a single temporary
bearing should not exceed 1,0 mm.
b) Elastomeric launching bearing pads
The laminated elastomeric launching bearing pads shall be designed in accordance with SABS 0326 and comply with the requirements of SABS
1806. The pads shall be fabricated from natural rubber or chloroprene with a shore hardness of 60° and be designed to compensate elastically
for local deviations of up to 2,0 mm in the sliding surface.
The formulation of the natural rubber or chloroprene shall be such that it does not mark the soffit of the deck. Details to be submitted to the
Engineer for approval.
The elastomeric cover over the outer steel plates shall be 3,0 mm.
The bearing pads shall be designed to safely accommodate the maximum deck reactions during launching, as given on the drawings, with a
maximum stress of 12 MPa.
The PTFE sliding surface bonded onto the elastomer shall be 2,0 mm thick and shall be thoroughly cleaned and lubricated immediately before
reuse.
The bearing pads shall be replaced as soon as the PTFE sliding layer tears or debonds or the pad is damaged to such an extent that it is no
longer serviceable.
Before a launch starts, at least one extra bearing pad shall be available at each temporary bearing, at any time. Notwithstanding this provision,
the number of pads provided shall be sufficient to complete the work.
During launching, the edge distance between the bearing pad and the edge of the deck soffit shall fall within the specified tolerance. The
Contractor shall specify in his method statement his procedures to control the edge distance.
A13.13.7.5 Platforms
At all of the supports, safe working platforms complete with access ladders and safety railings in compliance with current safety regulations and
OHS requirements shall be provided and maintained. The platforms shall not be removed before acceptance by the Engineer of the installation
of the permanent bearings and repair work to the supports.
Where necessary, access walkways to the platforms or direct access from the bridge deck shall be provided. If the platforms are damaged or
become unstable from any cause, they shall immediately be repaired at the Contractor’s expense.
If necessary, feeding trays for the elastomeric launching bearing pads shall be provided at each temporary bearing as part of the platform.
A13.13.7.6 Temporary supports

Temporary supports shall be located at the positions indicated on the drawings and be designed to resist the basic loads and, in order to limit the
risks, any additional loads the Contractor considers necessary to cater for construction conditions, possible seismic effects, settlements and
other incidental loads. If the support is of reinforced concrete, the design shall be in accordance with TMH-7 Part 3, and if in structural steel it
shall be designed to BS 5400 Part 3. A geotechnical appraisal report is required for any temporary support founding.
The design of the support shall incorporate a facility which will permit adjustment of the level of the temporary bearing to compensate for vertical
deformation of the support and for possible settlement of the foundations.
The founding conditions for the supports shall comply with the settlement criteria described in Clause A13.13.7.1b).
The position of the temporary support located between the deck construction area and the jacking abutment, shall not be moved without the
written approval of the Engineer.
A13.13.7.7 Stays
Where shown on the drawings, high piers shall be stayed with staying cables symmetrically arranged around the centre of the pier. The stays
shall be positively anchored to the top of the pier in a position that will not interfere with the working platform and at the other end, to the
foundation of the adjacent pier. For each pier, the stays shall be simultaneously tensioned to a force that will limit the maximum pier deflection
under launching to within the specified value without overstressing the pier. If during launching the limiting deflections are exceeded, or if the
pier deflection is to be zeroed before installation of the permanent bearings, the stays shall be re-tensioned as directed by the Engineer.
A13.13.7.8 Deck construction

a) General
This subsection covers the requirements for the sequential construction of the deck and its component parts. On completion of launching the
deck into its final position, the timing and sequence of the following remaining operations shall require the approval of the Engineer:
• Construction of deck diaphragms.
• Tensioning of draped pre-stressing tendons.
• Installation of permanent bearings.
• Construction of parapets, sidewalks and median island components.
• Installation of services and lighting (if required)
• Surfacing of decks.
• Installation of movement joints.

b) Control measures
Control measures shall be established and maintained to ensure that the work complies with the specified requirements. The measures shall be
carried out by a skilled person well versed in the operation of the systems and equipment used.
Precision survey equipment shall be capable of direct measurement to 1,0 mm accuracy and shall be made available to the Engineer whenever
required.
The level on the sliding surface of the temporary bearings shall be measured at regular intervals during the launching process as directed by the
Engineer and if the limiting vertical tolerance of ± 1,0 mm is exceeded, the bearing levels shall be adjusted to compensate for deformation and
settlement of the supports under the imposed loading.
Before casting any segment, the alignment and levels on the spine beams must be checked and corrected if the specified tolerances are
exceeded.
During installation of the permanent bearings or during the adjustment or replacement of temporary bearings, the jacking forces and
corresponding amount by which the deck is lifted, shall be accurately recorded and submitted to the Engineer for correlation purposes.
If at any instant a disproportionate variation is detected, the jacking operation shall be stopped immediately and the cause thereof ascertained
and corrected before jacking is restarted.
The results of the control checks shall be reported to the Engineer systematically throughout the construction process in a manner to be agreed.
The total construction loads on the superstructure before all the pre-stressing is completed, shall not exceed 0,5 kN/m 2 on both the top and
bottom slabs of the box girder.
c) Casting of the deck
Where the deck consists of a box girder, it shall be cast in two stages with a construction joint located between the webs and the top deck slab.
Each casting stage shall extend over the full length of a segment and no intermediate vertical or inclined construction joints will be permitted.
The time lapse between the placing of the concrete in the two stages shall not exceed three days.
The first segment shall be match cast with the launching girder and shall include all modifications to the end of the deck to accommodate the
launching girder.
All web widenings required to accommodate the pre-stressing anchorages shall be cast together with the web.
d) Launching girder installation
The launching girder shall be fixed to the leading deck segment by means of either pre-stressing tendons or friction bolts cast into the concrete.
The maximum stress in the tendons or bolts shall not exceed 60 % of the characteristic strength of the steel.
Where pre-stressing is used, the force in the tendons shall be monitored 4 weeks after installation and thereafter at intervals of 3 months.
The prestressing force provided shall prevent lift-off at the concrete to steel interface under the worst loading combination.
The interface between the sliding surface of the girder and the soffit of the concrete deck shall be flush. Any deviation shall be corrected over a
distance of 100 times the deviation.
e) Tensioning of concentric pre-stressing tendons
The tensioning of the concentric tendons shall not be undertaken before the concrete in the deck segment has attained a strength of 35MPa. In
this regard, the compressive strength shall be based on the test cubes that have been manufactured and cured on site adjacent to the launch
yard. Sufficient test cubes shall be manufactured to ensure that a test result reflects the required sample size.
The sequence of tensioning the individual concentric tendons shall be undertaken symmetrically around the centroid of the deck cross section.
Grouting of tendons shall be carried out immediately after the launch of the segment.
f) Launching of deck
The launching operation shall be controlled by a person with extensive and appropriate experience in the construction system and procedure.
Launching of the segment may commence immediately after all the concentric pre-stressing tendons have been tensioned and the Engineer is
satisfied that all requirements in terms of the contract have been satisfied.
The position at which the bridge deck is locked shall not be more than 4,0 m from the construction joint between the segment still in the
formwork and the segment immediately ahead of it.
A mechanism shall be provided for temporarily anchoring the completed deck in position.
Pulling back operations shall be carried out under strict supervision and in the presence of the Engineer.
g) Construction of deck diaphragms
The deck diaphragms shall be cast as detailed on the drawings or in the Contract Documentation but always before the permanent bearings are
installed. Where the diaphragm is constructed after the construction of the box section, the soffit slab shall be rigidly supported to carry the
weight of the diaphragm concrete. Concrete shall be placed through the slots in the bridge deck.
h) Tensioning of draped pre-stressing tendons
The tensioning of the draped tendons shall not be undertaken before the concrete in the relevant deck diaphragms has attained a strength of
30MPa.
Stressing of the draped tendons shall be undertaken in two stages, sequentially along the length of the deck as follows:
Stage 1:
Tendons are to be stressed alternately in each web of span 1 until 50 % of the tendons have been tensioned.
Repeat for subsequent spans
Stage 2:
Complete stressing of unstressed tendons alternately in each web starting at the last span and working back to span 1.
i) Installation of permanent bearings
Details of the method to be used for the installation and securing of the permanent bearings in place shall be submitted to the Engineer for
consideration and approval.
After completing the deck prestressing and diaphragm prestressing, the permanent bearings shall be installed in the sequence shown on the
drawings
Lifting of the deck may take place at one support only at any one time and shall not commence before the concrete in the support diaphragm
has attained a strength of 30 MPa.
The bridge deck shall be lifted simultaneously on both sides to a maximum height of 10 mm and shall be raised in such a manner that the
relative difference in height, measured at corresponding positions along the soffit at the outside edges of the deck, does not exceed 2mm.
The bearings shall be installed to an accuracy of within 1,0 mm of the design level, the inclination of the bearings to within a tolerance of 1 in
1000 in any direction, and the orientation of the unidirectional bearings to within a tolerance of 1 in 200. The bearings shall be installed truly
horizontal.
In the connection of the bearing to the substructure and deck, reliance on friction or adhesives will not be permitted. Studs or protrusions shall
be used on the bearings and the deck and pier concrete scabbled to expose aggregate so that the failure plane due to horizontal loads passes
through the grout or concrete and not at an interface. The proposed detail shall be submitted to the Engineer for approval.
A non-shrink cementitious or epoxy mortar with a compressive strength of 20 MPa after 24 hours and 50 MPa at 28 days shall be used as
bedding for the bearings and for seating the deck on the bearings.
Precautions shall be taken to ensure that the deck cannot move whilst the bearings are being installed.
Where welding is used to secure the bearing in position, it shall comply with Clause A13.9.7.1h) of the standard specifications.
j) Construction of parapets, sidewalks and medians
Construction of the parapets, sidewalks and medians may commence simultaneously with the installation of the permanent bearings for the
relevant deck, unless shown otherwise on the drawings or directed by the Engineer.
k) Installation of movement joints
Installation of the movement joints may commence after the permanent bearings have been installed, the concrete in the abutment curtain walls
has gained full design strength and the asphalt surfacing has been completed.
A13.13.8.1 Monitoring
In the context of this specification, monitoring shall include all those functions performed during the process of launching the deck, which inter
alia includes the jacking of the bridge deck, measuring of support deflections, communication facilities and safety measures to be applied.
A detailed description of the proposed monitoring, together with the system for recording the jacking or restraining forces, incremental launching
rate and the operation of the fail-safe systems, shall be submitted to the Engineer.
If the launching, restraining or pull-back force should vary disproportionately from the anticipated force at any instant, the jacking operation shall
be stopped immediately and the cause thereof ascertained and corrected before jacking is restarted.
A supervisor, who is fully conversant with the sliding operation, potential malfunctions, and concomitant risk, shall be stationed at each support
where sliding takes place. They shall be responsible for continuously monitoring the pier deflections during each launch, ensuring that the
monitoring system is functioning correctly, and must be in radio contact with the launch controller at all times during the launching operation. No
launch shall commence before radio contact has been established between the launch controller and each supervisor. In addition, a panic button
shall be installed at each bearing where sliding is taking place, which when activated will immobilise the jacking operation.
Monitoring data shall be submitted to the Engineer on a daily basis.
It is in the Contractor’s interest to keep the tolerances as small as possible. This will reduce the loads and wear on the temporary works,
especially jacking forces and launching bearing pad wear.
a) Sliding surfaces in the deck casting area: These shall be checked and adjusted after each launch.
• Dimensions:
Width of the deck soffit on the plane of the side guides ................................................................................ ± 5,0 mm
Thickness of sliding formwork (Marineply) .................................................................................................... ± 1,0 mm
• Alignment:
Deviation of the centre line of the sliding surface from the specified line .... 1 in 1000 with maximum 5,0 mm deviation
• Levels:
Levels on a sliding surface ........................................................................................................................... ± 2,0 mm
Relative difference in level between two corresponding
points on two adjacent sliding surfaces ........................................................................................................... 1,0 mm
• Slope:
Slope in both directions on a sliding surface .................................................................................................. ± 0,1 %
b) Temporary bearings
• Position:
Transverse position of the side guides ......................................................................................................... ± 5,0 mm
Temporary bearings...................................................................................................................................... ± 5,0 mm
Elastomeric launching pads relative to deck soffit edge ................................................................................. ± 10 mm
• Levels:
Levels of bearings ........................................................................................................................................ ± 1,0 mm
Relative difference in level between the sliding surfaces
on corresponding bearings on consecutive piers, abutments or temporary supports ....................................... 4,0 mm
Relative difference in level between sliding surface on adjacent
bearings on the same pier, abutment or temporary support ............................................................................ 2,0 mm
• Slope:
Slope in both directions .................................................................................................................................. ± 0,1 %
• Dimensions:
Thickness of elastomeric launching bearing pads ........................................................................................ ± 1,0 mm
The thickness of the pads are to be accurately measured on site and similar thickness pads then used at each support.
Note: The cumulative effect of the tolerances listed in (1) and (2i) above shall not result in a relative difference of more than 5,0 mm in level
between two corresponding points on two adjacent sliding surfaces on the same pier, abutment or temporary support.
c) Jacks
Position: ............................................................................................................................................................... ± 25 mm
d) Launching girder nose
• Fabrication and assembly:
In accordance with Clause A13.11 of Chapter 13.
• Position:
Transverse position at deck connection ......................................................................................................... ± 10 mm
• Alignment:
Deviation of centre line of bottom flange from the specified line ... 3,0 mm over 12 m with maximum 5,0 mm deviation
Deviation of the front of the girder from the theoretical position during
launching, measured perpendicular and horizontally to the launching direction............................................ ± 100 mm
• Surface regularity:
Surface regularity of sliding surface ............................................................................................... 1,0 mm over 1,0 m
• Slope:
Slope in both directions on the sliding surface ................................................................................................ ± 0,1 %
A13.13.8.3 Quality control

The Contractor shall provide a method statement of the quality control required for the assessment of all temporary works. All costs associated
with testing of the temporary works shall be incorporated into the rates under this section, and shall not be deemed to form part of the
Contractor’s cost for a combined laboratory (if agreed to under the contract).
The Contractor, together with the designer of the temporary works, shall monitor the quality of the temporary works. The Engineer’s
responsibility will solely be to record the quality control being undertaken and inform the Contractor of any sub-standard work that arises.

B13.13 INCREMENTAL LAUNCHING OF BRIDGE DECKS
CONTENTS
B13.13.1 SCOPE
B13.13.3 GENERAL
B13.13.5 MATERIALS
B13.13.1 SCOPE
This Section covers the requirements for the incremental launching method of construction for bridge decks, and includes temporary work (i.e.
all works temporary in nature and required for construction of the permanent works), launching of the deck segments and the permanent work
not covered elsewhere in the Standard Specifications. Although the labour component associated with the various construction activities is high,
it is deemed to be of a specialist nature and therefore not suitable for labour enhanced work.
B13.13.3 GENERAL

B13.13.5 MATERIALS



C13.13 INCREMENTAL LAUNCHING OF BRIDGE DECKS
(i) Preamble
None.
pay items.
C13.13.1 Temporary bridge segment casting yard:
C13.13.1.1 Installation (Description of Structure) lump Sum

The tendered lump sum shall include full compensation for the supply of all material, labour, equipment etc., for the installation of the access
road, casting bed, temporary supports, all piling (if required), adjustable spine beam supports, reinforced or plain concrete work, drainage of the
area and the clearing of the area on completion. The tendered rate shall include full compensation for all design, fabrication, erection and
removal of all temporary works and earthworks associated with the incremental launching, including modification of the permanent works that is
not measured elsewhere.
80 % of the rate will be paid when the construction area is complete and the final 10 % will be paid when the installation is removed from site.
Increment payments of 10 % pro rata to progress shall be certified by the Engineer during construction of the deck area.
C13.13.2 Cover to casting area:
C13.13.2.1 Provide cover (Description of Structure) lump sum
C13.13.2.2 Re-use (Description of Structure) lump sum

The tendered lumps sum shall include full compensation for the design, fabrication, supply and initial erection, for dismantling and re-assembly
and for the subsequent removal from site of the necessary protection for the deck casting area.
90 % of the rate will be paid on completion of the cover to the casting area and the remaining 10 % when the cover is removed from site.

C13.13.3 Launching girder:
C13.13.3.1 Provide launching girder (Description of Structure) lump sum

The tendered lump sums shall include full compensation for the design, drawings, fabrication, testing and certification, as well as transport, initial
installation in position and fixing the girder to the deck and for all pre-stressing, anchorages, labour, handling, material and plant, for dismantling,
transporting and re-erection, the subsequent removal from site of the launching girder and any repairs required to the end of the deck after
removal of the girder. No additional payment shall be made for a launching girder that is heavier than the design girder, and for any additional
costs associated with the heavier girder.
50 % of the rate will be paid when the launching girder is delivered to site, a further 40 % when it successfully reaches the first support pier and
the remaining 10 % when it is removed from site.
C13.13.4 Formwork assembly:
C13.13.4.1 Supply formwork assembly (Description of Structure) lump sum
The tendered lump sums shall include full compensation for the design, fabrication, supply and initial erection, for dismantling and re-assembly
and for the subsequent removal from site of the formwork assembly. The tendered amounts shall include the operation and maintenance of the
formwork assembly to achieve the required concrete finish. The internal and external formwork to the launched bridge deck shall not be
measured in other Sections: all formwork, concrete finish and curing costs shall be included in the pay items under Section A13.13, unless
measured elsewhere.
30 % of the rate will be paid when the formwork assembly is delivered to site, a further 60 % pro rata to physical progress with bridge deck
casting and the remaining 10 % when it is removed from site.
C13.13.5 Launching equipment:
C13.13.5.1 Supply launching equipment (Description of Structure) lump sum
The tendered lump sums shall include full compensation for the design, supply and installation of the launching equipment, which includes
control and monitoring equipment, for dismantling and re-assembly and for the subsequent removal from site of the equipment.
50 % of the rate will be paid when the equipment is delivered to site, a further 40 % pro rata to successful bridge deck launching and the
remaining 10 % when it is removed from site.
C13.13.6 Temporary bearings, side guides and launching pads:
C13.13.6.1 Supply temporary bearings number (No)
C13.13.6.2 Supply side guides number (No)
C13.13.6.3 Re-use of temporary bearings number (No)
C13.13.6.4 Re-use of side guides number (No)
The unit of measurement shall be the number of temporary supports. Note that a single temporary support as measured comprises both a
vertical and a horizontal temporary support component. At the permanent and temporary piers two temporary supports are generally required
per pier, and at least two sliding pads are required per temporary support.
The tendered amounts shall include full compensation for the design, fabrication, supply and installation of the temporary bearings and side
guides, for dismantling and re-erection and for the subsequent removal from site, and for the design, fabrication, supply and use of the launching
pads at each support, including the replacement of damaged launching pads.
C13.13.7 Platforms:
C13.13.7.1 Supply platforms (Description of Structure) number (No)
C13.13.7.2 Re-use (Description of Structure) number (No)
The unit of measurement shall be the number of access platforms and is equal to the number of permanent and temporary piers.
The tendered amounts shall include full compensation for the design, fabrication, supply and erection, for dismantling and re-erection, for the
subsequent dismantling and removal from site of the access platforms and for any repairs to holes and recesses in the piers required for the
support of the platforms.
80 % of the rate will be paid when the platforms are commissioned and the remaining 20 % when they are removed from site and the repairs to
the permanent works completed.
C13.13.8 Stay system for piers:
C13.13.8.1 Pier (description) number (No.)
The unit of measurement shall be the number of piers/supports required to be stayed during the launching operation.
The tendered rate shall include full compensation for the supply, installation, tensioning, adjusting and subsequent removal of the stays, for the
anchorages and the anchorage reinforcing, for any temporary or permanent work required for the installation and for the subsequent repairs to
any holes and recesses.
80 % of the amount will be paid when the stay is satisfactorily installed. The remaining 20 % will be paid when the launching operation is
complete, the stay is disconnected, repairs completed to the pier and the stay moved to another position or removed from site.
C13.13.9 Launching of deck segments:
C13.13.9.1 Structure (description) deck segments number (No)
The unit of measurement shall be the number of deck segments cast and launched regardless of the length of segment being launched.
The tendered rate shall include full compensation for the complete launching of the bridge deck segment, for the appropriate control measures,
measurement of pier deflections, the operation and maintenance of the equipment and instruments including the formwork assembly, for all
lubricants and any additional costs necessary for the execution of the work as well as for the management of the launching pads at the supports.
90 % of the amount will be paid when the segment is launched. The remaining 10 % will be paid when the concrete formed and unformed
surfaces has reached the required standard of finish.
C13.13.10 Temporary piers including piles and pilecap:
C13.13.10.1 Temporary piers (description) number (No)
The unit of measurement shall be the number of temporary piers provided. A temporary pier shall include all piles, pile cap, columns and bracing
required. Two columns are usually required per temporary pier.
The tendered rate for temporary piers shall include full compensation for all concrete, structural steel, formwork and reinforcement steel and for
all other materials, labour, plant and other incidentals required for constructing the temporary piers complete, and for demolition of the temporary
piers and temporary pilecaps after use. All works including concrete and reinforcement shall be removed to a minimum depth of 1,5 m below
ground level.
80 % of the amount will be paid once the temporary pier is constructed. The remaining 20 % will be paid once the temporary pier is removed.

D13.13 INCREMENTAL LAUNCHING OF BRIDGE DECKS
CONTENTS
D13.13.1 SCOPE
D13.13.2 GENERAL
D13.13.1 SCOPE
D13.13.2 GENERAL
a) Structural steel launching girder


a) Incremental launch system: Proven track record.
b) Temporary Bearings.

13.14 SPECIALIST STRUCTURES
CONTENTS
A13.14.1 SCOPE
A13.14.3 GENERAL
A13.14.5 MATERIALS

A13.14 SPECIALIST STRUCTURES

A13.14.1 SCOPE
This Section covers the work related to specialist structures.
Jacked structures - includes all structures that are constructed either partially or completely and are then jacked into their final position into or
under road embankments.
Cable support systems for structures can range from minor cable support systems for bridges to major cable stayed bridges.
Other specialist bridges including balanced cantilever and other complicated structures.
A13.14.3 GENERAL
The construction of specialist structures shall be carried out in terms of world best practice for the construction of these structures and specialist
specifications shall be included in the Contract Documentation which shall replace this Section as applicable.
A13.14.5 MATERIALS

B13.14 SPECIALIST STRUCTURES

C13.14 SPECIALIST STRUCTURES

D13.14 SPECIALIST STRUCTURES

South Africa
COTO
Officials


CHAPTER 14: REPAIR AND
REHABILITATION OF STRUCTURES
October 2020

FOREWORD

Published by:

industry.
Document versions:
Comments:
Please note:
TABLE OF CONTENTS
CHAPTER 14: REPAIR AND REHABILITATION OF STRUCTURES ................................................................. 14-1
14.1 ACCESS FOR BRIDGE REHABILITATION .................................................................................................. 14-1
14.2 CORROSION SURVEY METHODS AND TESTING OF NEAR SURFACE CONCRETE PROPERTIES.... 14-9
14.3 DEMOLITION AND REMOVAL OF STRUCTURAL CONCRETE AND STEELWORK ............................. 14-17
14.4 SURFACE AND STRUCTURAL REPAIR OF CONCRETE MEMBERS .................................................... 14-24

14.5 ANCHORING OF REINFORCEMENT, GROUTING AND CRACK INJECTION ........................................ 14-35

14.6 SPRAYED CONCRETE FOR STRUCTURES ............................................................................................. 14-48

14.7 PROTECTIVE COATINGS AND TREATMENTS FOR CONCRETE .......................................................... 14-62

14.8 EXTERNAL BONDING OF STEEL AND CARBON FIBRE ........................................................................ 14-73

14.9 REPAIR AND REPLACEMENT OF ANCILLARY STRUCTURAL ELEMENTS ........................................ 14-84

14.10 JACKING OF BRIDGE STRUCTURES ..................................................................................................... 14-93

14.11 REPAIR OF STEEL ELEMENTS ............................................................................................................. 14-100

PART C: MEASUREMENT AND PAYMENT ................................................................................................................................................ 14-103
PART D: GUARANTEES AND COMPLIANCE CERTIFICATES ................................................................................................................... 14-104
CHAPTER 14: REPAIR AND REHABILITATION OF STRUCTURES
14.1 ACCESS FOR BRIDGE REHABILITATION
CONTENTS
A14.1.1 SCOPE
A14.1.2 DEFINITIONS
A14.1.3 GENERAL
A14.1.5 MATERIALS
A14.1.8 WORKMANSHIP

A14.1 ACCESS FOR BRIDGE REHABILITATION

A14.1.1 SCOPE
This Section covers the requirements for the provision of suitable and safe access to all areas requiring concrete demolition, repair work or
rehabilitation of structures in accordance with the contract, and for inspections by the Engineer. It shall also include for the protection of passing
persons, animals and vehicles against injury or damage and prevention of damage and contamination of the environment.
A14.1.2 DEFINITIONS
Temporary works - shall be necessary for access to the work area and includes all foundations, scaffolding and support structures, working
platforms, cradles, fixtures to existing structural members, etc. required for the safe access to and execution of the work.
Mobile access unit - consists of a vehicle-mounted access gantry and work platform, including mobile crane type units.
Location - means a specific structure as a whole where rehabilitation work has to be carried out.
Structural element - shall be that particular part or parts of a structure, bridge, culvert, retaining wall, traffic barrier, gantry or light mast as
specified or indicated on drawings.
• Bridge elements consist of abutments, piers, foundations, piles, decks, parapets, bearings and joints.
• Culvert elements consist of floors, walls and decks.
• Retaining wall elements consist of foundations and walls.
• Median barriers consist of foundations and barrier walls.
• Gantries consist of foundations, stub column and masts.
Setting up at each structural element shall include all movement required from point to point on a particular element.
Screening the work - suitable metallic or non-metallic grids, boarding or fabric membranes shall be used to screen the work area and to
prevent falling debris from endangering the persons in the work area.
A14.1.3 GENERAL
The Contractor shall provide and will be responsible for safe access structures and work platforms to all areas or structural elements requiring
remedial work. The access and temporary works shall be designed, constructed and maintained in accordance with the current relevant safety
regulations, all in compliance with the Occupational Health and Safety Act and its applicable Regulations, and shall remain in place until removal
is authorised by the Engineer. Appropriate allowances shall be made for screening of the work and other protective measures required by the
various work activities.

Access and work platforms may be provided from overhead mobile access gantries or vehicles, or from temporary works supported from the
ground or fixed to structural elements.
Notwithstanding approval given by the Engineer for the design and drawings prepared by the Contractor and the acceptance of temporary works
including the working platform(s) and access structure(s) as constructed, the Contractor shall be solely responsible for the safety and adequacy
of the temporary works in terms of the occupation health and safety Act and shall indemnify and keep indemnified the Employer and Engineer
against any losses, damage to persons or property, all claims, demands, proceedings, damages, costs, charges and expenses whatsoever,
which may arise out of or in consequence of the design, construction, use and maintenance of the temporary works.
For works on, over, under or adjacent to any railway line which is controlled by Rail Authorities, the Contractor shall comply, inter alia, with the
requirements for the preparation and submission of drawings for falsework and formwork, and the submission of certificates for the proper
construction thereof, all in accordance with the latest Rail Authority Specifications. The Contractor shall submit to the Engineer the relevant
design details and drawings of the working platform(s) and access structures for comment and/or record purposes.
Roped access techniques shall not be permitted unless specified in the Contract Documentation. Where roped access is used, only persons
who are specialists in roped access may be used in accordance with (Section18) of the applicable construction regulations.
Complete method statements including Occupation Health and Safety, Environmental and risk assessments, shall be submitted to the Engineer
of techniques to be adopted for execution of the work before any work commences.
The Contractor shall comply with any additional imposed or physical restraints upon the means of access to and from the structure as stated in
the project specification and the drawings.
The Contractor shall provide access facilities for inspection and testing by the Engineer, including the inspection at the end of the defects liability
period. Any specific access facility required for the inspection at the end of the defects liability period shall be as indicated in the pricing
schedule.
Traffic control and safety measures shall be erected to protect the access structures as required and specified on the drawings.
These special traffic control measures are required to protect the working platforms these shall consist of gantries across the road with attached
flashing lights. In addition, the gantries shall be fitted with alarm systems to warn the workman on scaffolds working on the bridge to evacuate to
positions of safety. Sirens set off from the impacted gantry are the preferred warning system. The Contractor shall however put in place all other
measures deemed necessary to minimise his risk.

A14.1.4.1 General
The Contractor's design and drawings of the falsework for access shall comply with all requirements of the Construction Regulations.
The Contractor’s design of all falsework for access shall be carried out by an ECSA Registered Professional Engineer or Technologist with
relevant experience and shall be in accordance with but not limited to the loadings of the latest version of TMH7. The drawings and calculations
shall be submitted to the Engineer for approval at least 14 days prior to the commencement of the work. The design, erection and construction
of such temporary works shall be certified by an ECSA Registered Professional Engineer or Technologist on behalf of the Contractor shall
comply with the relevant safety regulations regarding strength and stability for all imposed loads that can be anticipated to arise from the
specified work activities.
The Contractor shall submit to the Engineer at least 14 days before work on the existing structure is scheduled for construction a detailed
analysis showing the effect of the stresses that will be induced on the permanent works by the Contractor’s chosen method of construction.
The cost of any additional work or material required as a result of the Contractor’s chosen method of construction shall be to the Contractor’s
account. No construction shall commence until the Engineer has given his written approval.
The Contractors registered professional shall monitor at regular intervals and also sign off on the erection of the falsework and formwork after
the erection thereof before the Engineer permits the work to proceed.
A14.1.4.2 Falsework
The Contractor shall make his own assessment of the allowable bearing pressure on the foundation material and shall design the footings and
falsework to prevent overloading, differential settlement and unacceptable overall settlement. In assessing the allowable bearing pressure, due
account shall be taken of the effect of wetting on the foundation material.
The Contractor’s falsework designer shall take account of the location of the structure and the possible ingress of water from sources such as
watercourses, water table and saturation due to rainfall and assess the resulting effects in bearing capacity.
In designing the falsework, cognizance shall also be taken of the redistribution of load which may occur on account of the effect of temperature,
wind force, flooding and debris.
Cognizance shall also be taken of the lateral forces which may be induced by earth platforms, required for the support of falsework on the
substructures resulting in temporary or permanent stresses for which the existing sub-structures have not been designed.
Particular attention shall be given to providing transverse and diagonal bracing as well as rib stiffeners on cross bearers.
A14.1.5 MATERIALS
All timber, structural steel and scaffolding used shall be free from defects that may prejudice the stability of the working platform(s) and access
structures. All materials used for temporary access shall be certified and approved by the designer and copied to the Engineer. The jacks,
devices, clamps and fittings shall all be in good working order and of adequate design and strength.
The type, grade and condition of the material shall be subject to the designer’s approval and submitted to the Engineer for the record.

A14.1.6.1 Mobile access units
Access structures and work platforms mounted and operated from a mobile support base shall be of an approved type and capacity for the
intended use. The unit shall at all times be operated within the recommended limits in terms of reach and capacity and within all their limitations
as stated by the manufacturer or the authority responsible for the operation and maintenance of the access unit. The unit shall be maintained
and serviced by the Contractor up to completion of the works. The operator of the vehicle shall be suitably qualified and certified to operate the
unit.
A14.1.6.2 Scaffolds, platforms and cradles

Temporary works entailing scaffolds, platforms and cradles providing access to the work area shall be assembled and constructed from
materials and structural sections complying with the relevant material specifications. The temporary works shall be designed, erected, operated,
maintained and dismantled so as to ensure safe working conditions for all site personnel, and where necessary the safety of the general public
having access to the site. Traffic safety measures shall be in place before the work commences.

All temporary access structures and work platforms and associated works shall be erected, modified, maintained and dismantled under the
direction of an experienced and competent supervisor and safety officer.
Prior to using any temporary access structure or facility, and at regular intervals thereafter, or following unforeseen circumstances, the
temporary works shall be inspected and certified by a suitably experienced and qualified person on behalf of the Contractor.
To ensure the safety of, and to prevent injury or damage to passing persons, vehicles, animals, etc. the temporary works shall be enclosed with
a suitable screening membrane or boarding where necessary to contain material or work equipment within the limits of the restricted work area.
Suitable debris containers and chutes shall be provided to assist in the removal of debris and unusable or rejected materials.
Where temporary works are to be fixed to, or supported from an existing permanent structure, the location shall be subject to the approval by
the Engineer. Such temporary works shall be removed when the work is completed and any holes, surface damage or blemishes arising from
the fixture thereof to the inspected structure shall be repaired to the surface finish of the adjacent surface to the satisfaction of the Engineer.
The Contractor shall submit a Method Statement including Risk Assessments required in terms of the Occupation Health and Safety Act and
also provide for all requirements required in terms of the Environmental Management Plan.
A14.1.8 WORKMANSHIP
The Contractor shall, prior to dispatching the mobile access unit to the site, provide certification from the manufacturer or the operating authority
that the unit has been thoroughly inspected and serviced, that the unit is functioning properly and that it complies with the relevant safety
regulations and that the operator has been certified to operate the unit. After the erection for access purposes and before usage by the
workmen the works shall be certified by the designer in terms with compliance with the specifications and is suitable for its intended use. A copy
of the certification shall be delivered to the Engineer.

B14.1 ACCESS FOR BRIDGE REHABILITATION
CONTENTS
B14.1.1 SCOPE
B14.1.2 DEFINITIONS
B14.1.3 GENERAL
B14.1.5 MATERIALS
B14.1.8 WORKMANSHIP
B14.1.1 SCOPE
Access for bridge rehabilitation through mechanised means, is deemed to be specialised activity and generally not suitable for labour enhanced
work, however the traffic accommodation related to access requirements can be considered to be a labour enhanced activity and is covered
under Section B1.1 of Chapter 1. The temporary works associated with scaffolding and platform erection is executed by labour with the relevant
skills set and is deemed to be a labour enhanced activity.
B14.1.2 DEFINITIONS
B14.1.3 GENERAL

B14.1.5 MATERIALS


B14.1.8 WORKMANSHIP

C14.1 ACCESS FOR BRIDGE REHABILITATION
(i) Preamble
None.
products.
Accommodation of vehicular and pedestrian traffic at access Section C1.5 of Chapter 1 - All
C14.1.7
structures applicable items

The following payment items shall include full compensation for all the works items associated with the provision of suitable safe access to all
areas on site.
C14.1.1 Temporary access structures and work platforms (by element)

C14.1.1.1 Access and platforms to locations as described as well as dismantling and removal at
completion (heights assessed by Contractor)
(a) (Description of bridge or structures given)
(i) (Element of work requiring access described) number (No)
(ii) (Etc. for other elements of work) number (No)
(b) Etc. for other bridges or structures)
(i) (Element of work requiring access described) number (No)
(ii) (Etc. for other elements of work) number (No)

The unit of measurement for each item shall be the lump sum.
The height of the required access platforms can be estimated from the drawings but must be confirmed on site. The heights must be assessed
by the Contractor at the time of tender.
The tendered amount shall include full compensation for design, supply, fabrication, erection, dismantling, movement and for all labour,
materials, and equipment required for the above works including the inspections, supervision by the safety officer and the maintenance of the
temporary access structure and work platform.
Payment shall be made on the following basis: - 70 % of the lump sum on erection of access structures
- 30 % of the lump sum on removal of access structures
Payment shall not be made for re-erection of access structures.
C14.1.2 Mobile access units
C14.1.2.1 Establishment of mobile access unit on site (description of type of unit) lump sum
C14.1.2.2 Setting up of mobile access unit at each structure location and removal after completion number (No)
C14.1.2.3 Operation of mobile access unit during repair work at each location (structure) days
C14.1.2.4 Operation of mobile access unit during inspections by the Engineer hours (h)
C14.1.2.5 De-establishing and removal of mobile access unit from site after completion of work lump sum
The unit of measurement for each item shall be the lump sum, number, days or hours as indicated and shall be paid proportionately as the work
progresses.
The tendered amounts and rates shall include full compensation for all labour, plant and equipment required to procure, transport to site and to
establish the mobile access unit including all costs related to inspection, operation and maintenance of the unit on site.
The tendered rate for items C14.1.2.1 to C14.1.2.5 shall cover all costs necessary for establishing and de-establishing of the mobile access unit
on site.
The tendered rate for item C14.1.2.2 shall cover the cost for setting up of the mobile unit at each of the number of locations scheduled, and
removal after completion of the work at the location.
The tendered sum for item C14.1.2.3 shall cover all costs for operating the mobile access unit on location for the full time required to complete
the repairs.
The tendered rate for item C14.1.2.4 shall cover the cost of operation of the mobile access unit as required by the Engineer. No payment shall
be considered for this item if the Engineer requires the use of the mobile access unit while it is on location for the normal work to be done under
the contract and not specially re-established on the location for the purpose of inspection only.
Items C14.1.2.1 and C14.1.2.5 shall not apply to times when the mobile access unit is in operation on site for the repair works when it is possible
to be simultaneously also be used for inspection by the Engineer. The Contractor is to co-ordinate with the Engineer to ensure no unnecessary
establishment or de-establishments.
C14.1.3 Access at end of defects liability period (description of location) lump sum
The unit of measurement shall be the lump sum for access to each site or structural elements at the end of the Defects Liability Period as
ordered by the Engineer.
The tendered amount shall include full compensation for all labour, material, plant or equipment including plant operators required to provide
suitable and safe access for the Engineer to carry out the necessary inspections as measured in the pricing schedule.
C14.1.4 Attendance by (relevant authority)

C14.1.4.1 Prime cost sum to allow for attendance by relevant authority to obtain access near electrified prime cost sum
railway lines or other relevant authorities as required (give description of bridge)
C14.1.4.2 Percentage on prime cost sum for charges and profits percentage (%)
A prime cost sum is provided in the pricing schedule to cover the cost of the attendance as required and approved by the Engineer.
Payment for obtaining this service shall be in accordance with the provisions of the General Conditions of Contract.

C14.1.5 Provision of designs and drawings of access structures and platforms by an ECSA lump sum
Registered Professional Engineer or Technologist (description of member to which
applicable)

The unit of measurement shall be the lump sum and shall be paid in two payments of 50 % on submission of the access structures and
platform designs and the second 50 % on complete removal of all the access structures and platforms.
The tendered rates shall include full compensation for procuring and provision of all drawings for the access structures and platforms
designs by an ECSA Registered Professional Engineer or Technologist, including inspections, supervision and certification where
applicable, all labour, material, travelling and incidentals, and the signing off on the erection of the access structures and platforms including
submission of all certificates as specified.

C14.1.6 Provision of a safety gantry with warning system (description of type of gantry, size and number (No)
location)
The unit of measurement shall be the lump sum for each complete safety gantry erected.
The tender amount shall include full compensation for design supply, fabrication, erection, dismantling and for all labour materials and plant or
equipment required fabricate, supply, erect and dismantle the safety gantry in its location as specified.

C14.1.7 Accommodation of Vehicular and Pedestrian Traffic at Access Structures lump sum
The unit of measurement shall be the lump sum and shall be paid in three payments of 50 % on setting up of the accommodation of traffic
measures and the second 20 % on complete removal of all the traffic accommodation measures and the final 30 % at the end of the defects
liability period.
The tendered rates shall include full compensation for procuring and provision of all road signs and other measures required in accordance
with Chapter 1 for accommodation of vehicular and pedestrian traffic during the works and the accommodation of traffic measures required
for the defects liability inspection. The tendered rate shall also include all labour, material, travelling and incidentals, and the removal the
road signs and other measures after the completion of the works to the satisfaction of the Engineer.

D14.1 ACCESS FOR BRIDGE REHABILITATION
CONTENTS
D14.1.1 SCOPE
D14.1.2 GENERAL
D14.1.1 SCOPE
Note that the requirements for performance specifications are not limited to that given in Part A only but includes all of the requirements in the
D14.1.2 GENERAL
The Contractor shall, within 28 days of entering into the contract with the Employer, submit to the Engineer conformance documentation related to
the specifications.
a. Scaffolding members.
b. Timber scaffolding members.
c. Jacks, devices, clamps and fitting.
d. Mobile Platform / Hanging Access Platform Certificates.

Certification for all falsework for access by a suitable experienced ECSA Registered Professional Engineer or Technologist shall be required.

Performance based specifications shall be contained in the Contract Documentation for the project if applicable. Method Statements shall be drawn
up by the Contractor’s designer and submitted to the Engineer for approval.
The Contractor shall accept full responsibility for the design, erection, usage and removal of the plant and equipment from site after completion.

14.2 CORROSION SURVEY METHODS AND TESTING OF NEAR
SURFACE CONCRETE PROPERTIES
CONTENTS
A14.2.1 SCOPE
A14.2.2 DEFINITIONS
A14.2.3 GENERAL
A14.2.5 MATERIALS
A14.2.8 WORKMANSHIP

A14.2 CORROSION SURVEY METHODS AND TESTING OF NEAR SURFACE

CONCRETE PROPERTIES
A14.2.1 SCOPE
This Section covers the test methods and requirements to determine cover over reinforcement and to evaluate specific concrete properties,
such as compressive strength, ingress of aggressive chemicals and environmental agents, and common reinforcement corrosion
methodologies, that are generally assessed from the surface of an existing structural member. Specialised techniques not included in this
specification, such as petrographic tests, Alkali-silica reaction (ASR) tests, thermography, radiography, ground penetrating radar and vibration-
or acoustic-based structural assessments, shall be provided in the Contract Documentation.
A14.2.2 DEFINITIONS
A14.2.3 GENERAL
The Engineer will specify what provision must be made to inspect and survey exposed concrete surfaces via a sampling plan. The Contractor
shall carry out appropriate in situ or laboratory tests as stipulated in the sampling plan to determine appropriate remedial work. The Contractor
shall make allowance in his programme for the time required to carry out surveys, laboratory tests and the reporting of results prior to
commencing with repairs.
The Contractor shall provide suitable and safe access to enable the Engineer to carry out a close inspection of all specified concrete surfaces.
General access requirements shall be measured and paid for under Section A14.1.
A14.2.5 MATERIALS
All materials utilised to repair any survey or testing locations, shall comply with the requirements of Section A14.4 or as directed by the
Engineer.
The following chemicals shall be standards for testing concrete according to the standard methods presented in this Section:

A14.2.5.1 Reference pH indicator solutions used to determine carbonation depth
The pH indicator solution shall consist of either:
a) Phenolphthalein indicator solution comprising 1,0 g phenolphthalein dissolved in 50 to 70 mℓ ethyl alcohol and diluted to 100 mℓ with
neutral distilled or deionised water; or
b) Thymolphthalein indicator solution comprising 1,0 g thymolphthalein dissolved in 50 to 70 mℓ ethyl alcohol and diluted to 100 mℓ with
neutral distilled or deionised water.
A14.2.5.2 Laboratory chemicals used to determine chloride content

The chemicals used to determine chloride content shall consist of:
a) Deionised water with an electrical conductivity less than 2 µS/cm;
b) Nitric Acid (5 mol/l);
c) Silver Nitrate solution (0,02 mol/l);
d) Ammonium thiocyanate (NH4SCN) solution (0,1 mol/l);
e) Ammonium ferric sulfate indicator solution (100 mℓ of a cold saturated solution of NH4Fe (SO4)2 and 10 mℓ diluted nitric acid); and
f) 3,5,5-triethylexanol; or
g) Additional reagents as may be required when using the potentiometric method (refer Clause A14.2.7.4b).

All cover meter devices shall comply with BS 1881 Part 204 or SS – EN206.
All equipment, tools and devices used to obtain concrete samples from structures shall be based on proven and accepted technology within the
industry. The Contractor shall note the particular requirements of safely obtaining samples from the surface of soffit, i.e. working upside down,
and shall select for use the appropriate equipment for the intended purpose. The plant, equipment, tools and accessories shall be inspected
and maintained on a regular basis to ensure that they remain in good working order, function efficiently, and that safety is not compromised.

Sampling shall be carried out according to the plan prepared for the assessment or repair works, with due cognisance of the particular
requirements for each test. The sampling plan shall specify the approximate number, location and depth of samples, including depth increments
for specific tests. The Contractor shall be responsible to perform on site checking to ensure:
a) that concrete to be sampled is representative of the elements under investigation;
b) to confirm the location of reinforcement;
c) to avoid damage to reinforcement during sampling; and
d) to ensure that the load bearing capacity of the structure is maintained at all times.
The generally accepted concrete test methods and corrosion survey techniques are presented below.
A14.2.7.1 Delamination survey

Physical delamination surveys, comprising of hammer tapping (by hand for vertical, overhead and small areas) or chain drag (using a robust
steel chain for large flat areas), are commonly used to quantify and locate general areas of delamination in concrete. Skilled operators are
required to perform the surveys and to identify hollow sounding areas, but the methods may under-estimate the full extent of internal damage.
Physical delamination surveys may be supplemented with other techniques, such as radar or ultrasonic measurements or coring and specimen
extraction, on a case-by-case basis.
Hammer tapping shall be carried out by striking the concrete with a hammer with mass of at least 1,0 kg and recording the location of hollow
sounding areas. For plane concrete surfaces, the concrete face shall be sounded at approximately 300 mm centres in each direction. For
columns, beams or similar members with faces less than 300 mm wide, each face shall be sounded near each edge or corner at approximately
300 mm centres along the members. Where a hollow sounding area is detected, its extent shall be determined by local tapping and its
periphery marked clearly on the face of the member.
A14.2.7.2 Cover over reinforcement

The cover survey shall be conducted using the manual, grid or block survey method using approved cover meter devices. The cover meter shall
be sufficient to record and mark the position of reinforcement, including the cover depth and bar diameter, in the vicinity of all tests identified in
the sampling plan. Should another cover survey method be proposed, for example linear or quick scan method, a calibration procedure shall be
conducted strictly according to Clause A20.1.5.1h) of Chapter 20 and shall be submitted to the Engineer for approval prior to use.
A14.2.7.3 Compressive strength determined from cores

Concrete core specimens shall be drilled, prepared and tested for compressive strength in accordance with SANS 3001-CO2-3. The correction
for embedded reinforcement transversely in the sample, if required, shall be permitted. The correction for excessive voids shall not be
permitted.
a) When compressive strength is evaluated relative to the specified characteristic cylinder strength, the desirable core sample length to
diameter ratio shall be 2:1. The correction for length to diameter shall not be permitted.
b) When compressive strength is evaluated relative to the specified characteristic cube strength, the desirable core sample length to diameter
ratio shall be 1:1 and the correction for length to diameter ratio shall be permitted.
The average compressive strength determined from cored specimens shall be calculated from a sample comprising a minimum of three core
specimens.

A14.2.7.4 Ingress of aggressive chemicals or environmental agents
a) Carbonation depth
The depth of carbonation shall be determined in accordance with EN 14630, as a general method to determine the loss of alkalinity caused by
carbonation or exposure to other acidic agents. Where other acidic causes may be present, further laboratory testing shall be required to
establish the mechanism of loss of alkalinity.
(i) Extraction of core sample
Core samples shall be drilled at locations, to the depths, indicated on the sampling plan. The core sample shall be dislodged
from the parent concrete with due care, such that the sample length is maximised. Blunt force, such as hitting the sample with a
chisel, shall not be utilised to dislodge the sample from the substrate. All core holes shall be repaired to the satisfaction of the
Engineer.
(ii) Preparation of core sample for carbonation depth measurement along the outer drilled core surface
The core sample shall be cleaned with a nylon bristle scrubbing brush and clean potable water within 24 hours of extracting the
core from the structure and the prepared surface shall be kept damp.
(iii) Preparation of core sample for carbonation depth measurement on the inner fractured core surface
The core sample shall be split along its drilled axis up to 7 days after extracting the core from the structure and cleaned with a
nylon bristle scrubbing brush and clean potable water and the prepared surface shall be kept damp.
(iv) Reference pH indicator solution
Core surfaces prepared for testing shall be maintained in a surface damp condition prior to the application of a pH indicator
solution. The pH indicator solution shall be applied within 1 hour after preparation of the core sample.
The pH indicator solution shall be stored in a sealed airtight container prior to, and after, use. Where phenolphthalein pH
indicator solution is used, the colourless depth from the exposed surface to the interface at which the concrete turns fuchsia-
coloured (colour variations from pink to deep red are common) shall be recorded as the carbonation depth. Where
thymolphthalein pH indicator is used, the colourless depth from the exposed surface to the interface at which the concrete turns
blue-coloured shall be recorded as the carbonation depth.
(v) Measurement, calculation and reporting of carbonation depth
The carbonation depth shall be measured and recorded within 30 seconds of spraying with an indicator solution. Both the
arithmetic mean and maximum carbonation depth shall be measured and reported to the nearest mm.
1. Carbonation depth measurement along the outer drilled core surface.
Where core sample outer diameter exceeds 25 mm but less than 50 mm, the carbonation depth shall be measured at
four discrete locations equally distributed around the perimeter of the core sample, and the arithmetic mean calculated
and reported as the mean carbonation depth. Where core sample outer diameter, exceeds 50 mm, the carbonation depth
shall be measured at eight discrete locations equally distributed around the perimeter of the core sample and the
arithmetic mean calculated and reported as the mean carbonation depth.
2. Carbonation depth measurement on the inner fractured core surface or fragment removed from the structure.
Where a fragment or core sample outer diameter exceeds 25 mm, but less than 50 mm, the carbonation depth shall be
measured at three discrete locations equally distributed along the fractured surface of one portion of the sample, and the
arithmetic mean calculated and reported as the mean carbonation depth. Where a fragment or core sample outer
diameter exceeds 50 mm, the carbonation depth shall be measured at four discrete locations equally distributed along
the fractured surface of one portion of the sample and the arithmetic mean calculated and reported as the mean
carbonation depth.
(vi) Reuse of core sample for further testing
1. After carbonation depth measurement along the outer drilled core surface.
The core may not be reused to perform any chemical, electro-chemical or corrosion-survey measurements due to
probable contamination of the sample and shall be discarded. However, the core sample may be reused to determine
compressive strength, if required and of suitable dimensions.
2. After carbonation depth measurement on the inner fractured core surface
The portion of core used for carbonation testing may not be reused to perform any chemical, electro-chemical or
corrosion-survey measurements due to probable contamination of the sample and shall be discarded. The untested
portion of core may be used for other chemical tests.
b) Chloride content
The total acid soluble chloride content of hardened concrete or mortar shall be determined in accordance with EN 14629. This method may be
used on samples of powder obtained from either by drilling or from cores or fragments removed from concrete structures using nominal dry
processes.
(i) Taking core samples, or fragments removed from the structure, and processing into powder
The determination of chloride profiles related to the distance from the concrete surface, core samples or fragments removed
from the structure, may be cut into slices as specified in the sampling plan, using dry processes, or may be ground in increments
to obtain powder samples.
The slices of concrete shall be ground to a fine powder to pass a 1,0 mm sieve, and then homogenised for the particular depth
increment and sample under investigation. The ground sample shall be dried in an oven to constant weight at 105 ± 5°C and
then allowed to cool to room temperature, for example in a desiccator.

(ii) Collecting powder samples
Powder samples shall be collected using a hand-held rotary drill, and the diameter of the drilling tool along with the number of
drill holes shall ensure that a suitable sample size is determined. The minimum total sample size of collected powder is 20
grams to ensure that it is representative of all the concrete constituents at the sampling location. For concrete containing
aggregates of a maximum size of 20 mm, a 20 mm drill should be used. Typically, a drill diameter of 20 mm and two holes is
normally sufficient to provide 1,0 g of powder per mm depth of increment. For larger aggregate sizes a larger drill diameter and
sample size should be used.
(iii) Determining and reporting the chloride content
The chloride content shall be determined using either Volhard’s method or potentiometric titration in accordance with EN 14629.
The chloride content shall be reported for each depth increment in accordance with the sampling plan.
A14.2.7.5 Corrosion risk assessment

The corrosion risk assessment techniques should be interpreted in the context of complementary data from the reinforced concrete structure,
i.e. cover and ingress of aggressive chemicals or environmental agents, by specialists or skilled Engineers experienced in the field of corrosion
testing and structural evaluation.
a) Half-cell potential measurements
Half-cell potentials shall be carried out in accordance with recommendations published by RILEM TC 154-EMC “Half-cell potential
measurements – Potential mapping on reinforced concrete structures”. The saturated copper-copper sulfate electrode (CSE) is recommended
for all atmospheric measurements, and the silver chloride electrode (SSCE) for damp or wet elements. All half-cell potential measurements
shall be reported as CSE-equivalence.
b) Surface resistivity measurements
The surface resistivity shall be carried out in accordance with recommendations published by RILEM TC 154-EMC “Test methods for on-site
measurement of resistivity of concrete”. A four-probe arrangement, with the ability to geometrically vary the spacing of the probes, is desirable.
The resistivity device shall be used in locations where no or minimum reinforcement is present in the concrete and shall preferably not be used
in an orientation parallel to the reinforcement, i.e. the four-probe arrangement shall be used diagonally inside the reinforcement mesh wherever
possible.
c) Corrosion rate measurements
The corrosion rate measurement shall be carried out in accordance with recommendations published by RILEM TC 154-EMC “Test methods for
on-site corrosion rate measurement of steel reinforcement in concrete by means of the polarization resistance method”. The corrosion rate
equipment shall utilise either a galvanostat or potentiostat as a means of controlling and measuring potential and current.
A14.2.7.6 Repair of sample and test locations

The concrete surfaces of sampling and test locations shall be prepared in accordance with Clause A14.4.7.1a), and then cleaned with minimum
250-bar high-pressure water jet as a final preparation. All reinforcement shall be prepared in accordance with Clause A14.4.7.1b). The concrete
surface should present as dark matt, without glistening or shiny water films and should not be allowed to dry out before the application of the
repair system.
a) For repairs up to 50 mm deep
The repair shall be executed in accordance with Section A14.4. Structural (Class R3 or R4) or non-structural (Class R2) repair mortar in
accordance with EN 1504-3 including concrete restoration in accordance with Principle 3 – Methods 3.1 and 3.2. The concrete restoration
system shall include all bonding agents, treatments and curing measures in accordance with the manufacturer’s instructions.
b) For repairs greater than 50 mm deep
The repair shall be executed in two stages in accordance with Section A14.4. The first stage shall include the application of structural (Class R3
or R4) or non-structural (Class R2) repair mortar to fill the void up to 30 mm to 50 mm from the outer surface. Once the first stage repair mortar
has hardened, the second stage may be completed using a structural (Class R3 or R4) or non-structural (Class R2) repair mortar in accordance
with EN 1504-3 Principle 3 – Methods 3.1 and 3.2. The concrete restoration system shall include all adhesion promoting treatments,
reinforcement protection treatments and curing measures in accordance with the manufacturer’s instructions.
A14.2.8 WORKMANSHIP
The Contractor shall prepare an agreed reference grid of lines on the concrete surface to be tested and the Engineer will supply the design
sampling plan. The location of each test, as amended by the Contractor, shall be recorded on an approved reference drawing along with the
processed test result. All substandard areas or areas of potential contamination or corrosion risk shall be agreed with the Engineer and marked
on the structure by the Contractor.

B14.2 CORROSION SURVEY METHODS AND TESTING OF NEAR SURFACE
CONCRETE PROPERTIES
CONTENTS
B14.2.1 SCOPE
B14.2.2 DEFINITIONS
B14.2.3 GENERAL
B14.2.5 MATERIALS
B14.2.8 WORKMANSHIP
B14.2.1 SCOPE
This Section covers the test methods and requirements to determine cover over reinforcement and to evaluate specific concrete properties. Due
to the specialised nature of the activities it is not suitable for labour enhanced work.
B14.2.2 DEFINITIONS
B14.2.3 GENERAL

B14.2.5 MATERIALS


B14.2.8 WORKMANSHIP

C14.2 CORROSION SURVEY METHODS AND TESTING OF NEAR SURFACE
CONCRETE PROPERTIES
(i) Preamble
None.
products.
The following payment items shall include full compensation for all the works items associated with the provision of suitable safe access to all
areas on site.
C14.2.1 Delamination Survey:
C14.2.1.1 using hammer tapping technique to (description) square metre (m2)
C14.2.1.2 using chain drag technique to (description) square metre (m2)
C14.2.1.3 using extracted core samples (description of location, core size and length) number (No.)
C14.2.1.4 using extracted core samples (description of location, core size and length) metre (m)
The unit of measurement shall be the square meter area of delamination tests carried out in accordance with Clause A14.2.7.1 or the number or
metre length of concrete core.
The tendered rate shall include full compensation for all labour, material and testing equipment, transport to a laboratory, preparation of the
sample and testing, data capturing and data processing required to execute the work and the recording and presentation of results, including
furnishing of record drawings, and the repair of all specimen and test locations.
C14.2.2 Concrete cover survey
C14.2.2.1 (description of location on structure) square metre (m2)

The unit of measurement shall be the square metre of concrete surface surveyed by means of an approved covermeter using the block or grid
survey method, in accordance with Clause A14.2.7.2.
The tendered rate shall include full compensation for all labour, material and testing equipment required to execute the work and the recording of
results, including furnishing of record drawings, and the repair of all specimen and test locations.

C14.2.3 Concrete compressive strength
C14.2.3.1 using extracted core samples (description of location, core size and length) number (No)
C14.2.3.2 using extracted core samples (description of location, core size and length) metre (m)
The unit of measurement shall be the number or metre length of concrete core, transport to a laboratory, preparation of the specimen and
testing, in accordance with Clause A14.2.7.3. The tendered rate shall include full compensation for all labour, material and testing equipment
required to execute the work, the recording and reporting of results, including furnishing of record drawings, and the repair of all specimen and
test locations.
C14.2.4 Carbonation depth testing
C14.2.4.1 using extracted core samples or fragment removed for (description of location on structure) number (No)
The unit of measurement shall be the number of carbonation tests carried out in accordance with Clause A14.2.7.4a).
The tendered rate shall include full compensation for all labour, material and testing equipment required to execute the work, the recording of
results, including furnishing of record drawings, and the repair of all specimen and test locations.
C14.2.5 Chloride profile testing
C14.2.5.1 using extracted core samples or fragment removed for (description of location on structure) number (No)
The unit of measurement shall be the number of chloride tests carried out in accordance with Clause A14.2.7.4b).
The tendered rate shall include full compensation for all labour, material and equipment required to execute the work including all testing and
reporting by an approved laboratory, including furnishing of record drawings, and the repair of all specimen and test locations.
C14.2.6 Half-cell potential measurements

The unit of measurement shall be the square metre of concrete surface where half-cell potentials are determined in accordance with Clause
A14.2.7.5a).
The tendered rate shall include full compensation for all labour, material and equipment required to execute the work including all connections to
the reinforcement, testing and reporting by an approved specialist or laboratory, including furnishing of record drawings, and the repair of all
specimen, reinforcement connections and test locations.
C14.2.7 Surface resistivity measurements

The unit of measurement shall be the square metre of concrete surface where surface resistivity is determined in accordance with Clause
A14.2.7.5b).
The tendered rate shall include full compensation for all labour, material and equipment required to execute the work including all testing and
reporting by an approved specialist or laboratory, including furnishing of record drawings.
C14.2.8 Corrosion rate measurements
The unit of measurement shall be the square metre of concrete surface where corrosion rates are determined in accordance with Clause
A14.2.7.5c).
The tendered rate shall include full compensation for all labour, material and equipment required to execute the work including all connections to
the reinforcement, testing and reporting by an approved specialist or laboratory, including furnishing of record drawings, and the repair of all
specimen, reinforcement connections and test locations.

D14.2 CORROSION SURVEY METHODS AND TESTING OF NEAR SURFACE
CONCRETE PROPERTIES
CONTENTS
D14.2.1 SCOPE
D14.2.2 GENERAL

14.3 DEMOLITION AND REMOVAL OF STRUCTURAL CONCRETE
AND STEELWORK
CONTENTS
A14.3.1 SCOPE
A14.3.2 DEFINITIONS
A14.3.3 GENERAL
A14.3.5 MATERIALS
A14.3.8 WORKMANSHIP

A14.3 DEMOLITION AND REMOVAL OF STRUCTURAL CONCRETE AND

STEELWORK
A14.3.1 SCOPE
This Section covers the work in connection with the demolition of entire members of a concrete structure as well as cutting back concrete to
expose reinforcement and the initial preparation of the exposed surface. Surface and structural repair of concrete members is covered in
Section A14.4. This Section also covers the demolition and removal of steel structures and members.
A14.3.2 DEFINITIONS
Concrete and steel members or elements:
a) All references to concrete members shall include mass concrete, un-reinforced, reinforced and prestressed concrete members.
b) References to steel members shall include all structural steel members in structures.
Demolition of concrete and steel members or elements:
Demolition means the breaking up and removal of an entire concrete member or portion of a member or demolition and removal of an entire
structural steel member or element.
Removal of concrete and steel members or elements:
a) Removal of concrete means cutting back into the surface or end of a concrete element and the removal of unsound, damaged or
contaminated concrete, or the partial removal of concrete sections, to expose a sound surface for bonding new material for the repair or
extension of the concrete element.
b) Removal of steel members or elements means the cutting out of a steel member or element out of a steel structure.
A14.3.3 GENERAL
A14.3.3.1 Concrete members and elements
The work is this chapter includes the demolition of concrete members or elements either completely or partially. Complete demolition is usually
carried out for the replacement of a member or element of a structure in its entirety and partial demolition of member or element is carried out for
alterations or extensions to a structure.
Removal of small areas of concrete in partial demolitions is carried out for repairs of concrete members or elements.

A14.3.3.2 Structural steel
The demolition of structural steel members or elements can also be full demolition of a structure, member or element and is also carried out for
alterations, extensions or repairs on structural steel structures.

Where concrete members or elements are demolished or where concrete is removed from concrete sections, or where steel members or
elements are removed, the Contractor shall submit complete method statements for the method of execution of the works. These method
statements shall be submitted for approval by the Engineer at least 14 days prior to works being carried out.
A14.3.5 MATERIALS
All materials used in the demolition and removal of concrete elements, shall be handled, stored and used strictly in accordance with the
manufacturer’s instructions and the current Occupation Health and Safety Act and its regulations.

A14.3.6.1 General
All plant, equipment and tools used for the demolition of concrete elements or the removal of portions of existing concrete or the removal of
steel members or elements shall be based on proven and accepted technology within the industry. The plant, equipment, tools and accessories
shall be inspected and maintained on a regular basis to ensure that they remain in good working order, function efficiently, and that safety is not
compromised. All cutting and breaking tools shall be kept sharp to reduce the force required to break out concrete to a minimum.
The plant, equipment and tools used for the demolition or removal process shall be of the accepted type and capacity for the relevant
application. The suitability of the chosen method shall be demonstrated on a representative test section identified by the Engineer prior to the
execution of any programmed work.
A14.3.6.2 Access structures and working platforms

Where necessary, the Contractor shall provide suitable and safe temporary access structures, working platforms, debris collection and removal
chutes and bins, including protection screens where required, at each location where concrete has to be demolished or removed.
The temporary structures, platforms, chutes, etc. must be stable and of sufficient strength and rigidity to safely carry the imposed temporary
loads arising from the work activity, all as described in Section A14.1.

A14.3.7.1 Sequence of execution
The method and sequence of demolition or removal of concrete and structural steel shall be in accordance with the drawings or the approved
method statement submitted by the Contractor to the Engineer for approval.
Any temporary propping specified in the approved method statement and the drawings shall be securely positioned in accordance with each
stage of the demolition or removal sequence prior to commencement of the following stage.
Areas to be demolished shall be indicated by the Engineer or shown on the drawings.
A14.3.7.2 Site preparation and access

The necessary access and temporary support structures shall be in place prior to the commencement of demolition or removal of concrete or
structural steel. Screening and protective measures shall be established around the work area as necessary to ensure acceptable
Environmental, Occupation, Health and Safety conditions.
A14.3.7.3 Demolition of entire structural members

a) Concrete members
The demolition of entire concrete structures or major members of a structure shall employ techniques that do not damage the existing structure,
adjacent structures or structural members or elements the roadway below, nor contaminate the surrounding environment. The Contractor shall
ensure that any nuisance associated with his work activity is minimised by implementing appropriate precautions and measures to the approval
of the Engineer. Common nuisances associated with demolition and concrete removal include fumes, noise, dust, flying fragments, heat and
vibration.
Concrete members which are to be demolished completely shall be broken into suitably sized fragments to allow easy removal from site to an
approved disposal site.
Recommended demolition techniques include the use of concrete cutting equipment, percussion breakers, chisels or other approved
mechanical equipment, the use of thermal or hydraulic cutting techniques or by non-explosive chemical means, to ensure minimal damage (e.g.
micro-cracking) to the existing concrete. Demolition by explosive means shall normally not be acceptable and shall only be permitted subject to
the Engineer’s written approval. Water jet removal of concrete is preferred wherever this method is feasible.

b) Steel structures or members
The removal of entire structural steel structures or members shall be carried out using techniques which do not damage adjacent structures or
members. The Structural members to be demolished or removed completely shall be cut up into suitably sized sections and removed to suitable
scrap metal yards for re-cycling.
A14.3.7.4 Removal of concrete from structural elements

a) Cutting back concrete to a new finished surface
The concrete and reinforcement shall be cut back adequately to provide the prescribed concrete cover to the new finished surface as indicated
on the drawings or as directed by the Engineer. The technique used shall be suited to its intended purpose and shall not cause damage to the
remaining concrete member.
Only techniques that do not damage the inherent structure, bond or strength of the remaining sound concrete shall be used. Heavy duty
demolition equipment or thermal cutting techniques shall not be used closer than 100 mm from the final surface of the cut back as indicated on
the drawings. The remaining concrete shall be removed using approved mechanical equipment or preferably hydro demolition.
The fixed exposed contact surface shall be bounded by straight line edges cut at least 10 mm deep by a diamond cutting saw, angle grinder or
other approved equipment.
b) Cutting back concrete to expose reinforcement
Where a concrete member has to be joined or extended or replaced by new concrete, the concrete shall be carefully cut or broken from the
reinforcement bars to expose the bars to the dimensions and outline as shown on the drawings or as directed by the Engineer. Care shall be
taken not to damage or reduce the strength of the exposed bars or concrete member thereby making them unfit for use. The remaining
concrete contact surface shall be cut to a plane and even surface with exposed faces perpendicular to the horizontal face or side faces as
applicable.
The bounding lines of the cut concrete shall be straight and neatly cut to at least a depth of 10 mm using a diamond cutting saw, angle grinder
or other approved concrete cutting equipment.
A14.3.7.5 Removal of structural steel elements from existing structures

Where structural steel elements or members are removed from structures special cutting techniques shall be used to ensure the integrity of the
remaining steel structure. Temporary bracing and or members shall be welded or bolted into place as indicated on the drawings before such a
structural member or element is removed from the structure.
No work shall be carried out unless a complete method statement is submitted to the Engineer for approval and which shall include all
Occupational Health and Safety requirements and a Risk Assessment.
A14.3.7.6 Removal of metal sections embedded in concrete

Metal sections including steel reinforcement that are embedded in concrete members by means of grout pockets shall be removed by carefully
chipping out the embedment grout filling the pocket. Care shall be taken not to damage the structural concrete surrounding the pocket. Suitable
tools such as hand-held power tools with chisel bits or hand tools shall be used to carry out this work.
Following the removal of the metal section or steel reinforcement, all remaining grout shall be removed and the pocket cleaned out to expose
only solid concrete surfaces. The pocket shall be finally cleaned using high-pressure water jetting or oil-free compressed air to remove all loose
fragments of grout, or concrete aggregate before further work is carried out.
A14.3.7.7 Preparation of exposed contact surfaces (for extension of existing concrete elements
or construction of new concrete members)
All loose and shattered concrete, as well as foreign material such as oil, paint, grease, etc. shall be removed from the contact surface of old
concrete before new concrete is placed. The aggregate must be exposed to provide a good bonding surface.
The mechanically prepared concrete surface shall be cleaned by means of grit blasting or water jetting.
The breaking out and preparation of damaged, spalled and/or cracked concrete surfaces is described and measured under Sections A14.3 and
A14.4.
A14.3.7.8 Disposal of waste material

All waste materials, rubble, scrap and rubbish arising from the Contractor’s presence on site and/or the execution of the works shall be
disposed of weekly to a disposal site or scrap metal yard identified by the Contractor and approved by the Engineer in accordance with the EMP
requirements.
A14.3.8 WORKMANSHIP
The Contractor shall remove concrete to a planar, uniform surface with 25 mm maximum deviation from the level or dimension indicated on the
drawings unless otherwise approved by the Engineer. The outer edge of the contact surface shall consist of straight lines with maximum
deviation of 5,0 mm from straight, measured with a 1,0 m long straight edge, and shall be within 5,0 mm of the position indicated on the
drawings, or as instructed by the Engineer. Steel members to be removed shall be cut out and replaced to a tolerance of 2,0 mm and then be
welded or bolted into position.
A14.3.8.2 Trials
The Contractor shall carry out pre-construction trials with the proposed equipment to determine the suitability of the technique for the envisaged
application. The results shall be reported to the Engineer and shall be subject to the Engineer’s approval before the inclusion of such equipment
into the method statement for the execution of the works.
B14.3 DEMOLITION AND REMOVAL OF STRUCTURAL CONCRETE AND
STEELWORK
CONTENTS
B14.3.1 SCOPE
B14.3.2 DEFINITIONS
B14.3.3 GENERAL
B14.3.5 MATERIALS
B14.3.8 WORKMANSHIP
B14.3.1 SCOPE
This Section covers the work in connection with the demolition of entire members of a concrete structure as well as cutting back concrete to
expose reinforcement and the initial preparation of the exposed surface. Surface and structural repair of concrete members is covered in
Section A14.4. This Section also covers the demolition and removal of steel structures and members. It is suitable for labour enhanced work.
This part covers additional specifications to optimise the labour component of construction activities.
The removal of concrete for labour enhanced activities is limited to a surface area of 2,0 m2.
B14.3.2 DEFINITIONS
B14.3.3 GENERAL
The provisions of Part A shall apply, in addition to the following:
All concrete shall conform to the requirements of Section A13.4 of Chapter 13.
The demolition of discrete structural elements shall employ techniques that do not damage adjacent structures or structural components, nor
contaminate the surrounding environment.
The Contractor shall ensure that any nuisance associated with his work activity is minimized by implementing appropriate precautions and
measures. Common nuisances associated with demolition and concrete removal include fumes, noise, dust, flying fragments, heat and
vibration.
Water jet removal of concrete is preferred wherever possible. Demolition using explosives is not permitted.

Add to the provisions of Clause A14.3.4 the following:
For labour optimised construction, a separate method statement shall be prepared for every structure that is to be taken down or removed.
These method statements shall be drawn up by competent Contractor’s Representative with relevant experience and shall be submitted to the
Engineer for approval. The method statements shall be accompanied by drawings and calculations as needed for clarity.
B14.3.5 MATERIALS


B14.3.8 WORKMANSHIP

C14.3 DEMOLITION AND REMOVAL OF STRUCTURAL CONCRETE AND
STEELWORK
(i) Preamble
None.
pay items.
The following pay items shall include full compensation for all work associated with the demolition and removal of concrete structural elements
including initial preparation of concrete surfaces or portions thereof. General access, work platforms and associated temporary works are
covered in Section A14.1.
The quantities indicated in the pricing schedule are based on the dimensions shown on the drawings and on inspections carried out and
increased to allow for the quantity of work. It must, however, be accepted that the quantities of work actually done may vary significantly from the
scheduled quantities, and that the Contractor shall be deemed to have allowed in his tendered rates for such variations in quantities which can
be reasonably expected.
C14.3.1 Demolition of concrete members or elements
C14.3.1.1 Full member or element (location and description) cubic metre (m³)
C14.3.1.2 Partial member or element (location and description) cubic metre (m³)
C14.3.2 Demolition of concrete members or elements by labour enhanced construction
C14.3.2.1 Full member or element (location and description) cubic metre (m³)
C14.3.2.2 Partial member or element (location and description) cubic metre (m³)
The unit of measurement for items C14.3.1 and C14.3.2 is the cubic metre of concrete demolished, measured in its original position and shape
based on either full or partial demolition.

The tendered rate shall include full compensation for all labour, material, screening of the structure for safety and environmental protective
measures, equipment and plant as well as for all work and incidentals required to complete the work as specified and required to demolish the
concrete member and to load, transport and dispose the concrete segments and rubble at the nearest approved disposal site including overhaul
and any fees applicable at the site. Refer to Clause A14.3.7.3.

C14.3.3 Demolition of structural steel structures, members or elements (location and
description)
C14.3.3.1 Full member or element (location and description) ton
C14.3.3.2 Partial member or element (location and description) ton

C14.3.4 Demolition of structural steel structures, members or elements by labour optimised
construction (location and description)
C14.3.4.1 Full member or element (location and description) ton
C14.3.4.2 Partial member or element (location and description) ton

The unit of measurement for items C14.3.3 and C14.3.4 is the ton of structural steel removed measured in its original position based on either
full or partial demolition of a structure, structural member or element.
The tender rate shall include full compensation for all labour, material, screening of the structure and protective measures, equipment and plant
as well as for all work and incidentals required to remove the structural steel structure, member or element and to load, transport and dispose
the steel elements and rubble to the nearest approved disposal site or scrap metal yard including overhaul and any fees applicable at the site.
C14.3.5 Removal of metal sections embedded in concrete (description) number (No)

The unit of measurement shall be the number of metal sections removed.
The tendered rate shall include full compensation for all labour, materials, equipment, screening of the structure and protective measures,
required for the removal of the metal sections as described in Clause A14.3.7.6 and disposal of all rubble at an approved waste disposal site
including overhaul and any fees applicable at the site, and the cleaning of the pocket as specified in Clause A14.3.7.6.

C14.3.6 Establishment on site for hydro-demolition equipment lump sum
The tendered lump sum shall include full compensation for establishment on the site and the subsequent removal of all special equipment
and plant for the high pressure water demolition of defective concrete, the cost of which does not vary with the actual amount of work to be
done.
This work will be paid for by way of a lump sum, 75 % of which will become payable when all the equipment is on the site. The remaining 25
% will become payable after all the water demolition of concrete has been completed and the equipment has been removed from the site.

D14.3 DEMOLITION AND REMOVAL OF STRUCTURAL CONCRETE AND
STEELWORK
CONTENTS
D14.3.1 SCOPE
D14.3.2 GENERAL

14.4 SURFACE AND STRUCTURAL REPAIR OF CONCRETE
MEMBERS
CONTENTS
A14.4.1 SCOPE
A14.4.2 DEFINITIONS
A14.4.3 GENERAL
A14.4.5 MATERIALS
A14.4.8 WORKMANSHIP

A14.4 SURFACE AND STRUCTURAL REPAIR OF CONCRETE MEMBERS

A14.4.1 SCOPE
This Section covers the requirements for the surface and structural repair of structural concrete members. It covers the preparation of the
exposed concrete surface and reinforcement for the rehabilitation of the member, and the repair or replacement of concrete with cementitious
mortars, epoxy systems and proprietary concrete repair compounds.
The method for removal of defective or contaminated concrete, partial removal of concrete sections and the initial preparation of contact
surfaces are covered in Section A14.3.
A14.4.2 DEFINITIONS
Bonding agent - the component of a repair system used to promote adhesion of a repair mortar or concrete to a concrete substrate for the
purpose of achieving a permanent bond, which is not affected by moisture and strong alkalis in service.
Cementitious repair products and systems - hydraulic or polymer mortars, concretes and grouts.
High flow mortar or concrete - a repair product formulated to exhibit extremely high flow characteristics, outside the limits of normal methods
of test, and which flows through narrow gaps and around areas of congested reinforcement, without bleeding or segregation.
Smoothening coat - a fine mortar coating applied to a surface to fill voids, cracks, and cavities or to level an uneven surface. The purpose is to
prepare the surface for the application of protection systems (refer Section A14.7).
A14.4.3 GENERAL
This Section includes all the work and materials required to carry out the surface and structural repair of concrete members. The proprietary
repair materials which are specified are based on the EN 1504-3 specification which shall be used in conjunction with this specification.

Where the repair system comprises, in part, of a cementitious mortar or concrete, the material design and preconstruction laboratory results
shall be recorded and submitted to the Engineer for approval prior to the commencement of the repair activities. The surface and structural
repair activities shall only commence after the approval of the material design. The Contractor shall allow sufficient time in his programme for
the material design, EN 1504 compliance verification and approval of the repair system.

A14.4.5 MATERIALS
A14.4.5.1 General
Both cementitious-based and epoxy-based repair systems are described in this specification. In particular, cementitious repair systems may
comprise either of a proprietary system conforming to the specification or a site-based formulation and performance tested with the relevant
requirements of this Section.
A14.4.5.2 Cementitious mortar or concrete

The cementitious repair mortar shall comply with the strength requirements of the concrete in the structural member to be repaired. The
water/cement (w/c) ratio shall not exceed 0,5 and guidelines for the composition of mortars and concretes consisting of different aggregate sizes
shall be in accordance with the requirement of Section A14.4.
The Contractor shall be responsible for the final design of the repair mix and shall submit a test report by an approved testing laboratory to the
Engineer for approval prior to its use in the permanent works. All the test results shall be incorporated in the standard concrete mix design approval
form.
Materials used in the cementitious mortar or concrete shall comply with the following requirements:
a) Cement
Cement shall comply with SANS 50197-1 (EN 197-1) with a strength class of 32,5 or greater, and a rate of strength gain N or greater. Cement
shall hold valid certification in the form of a Letter of Authority issued as certified approval pursuant to the Compulsory Specification for cement
published by Government Notice R.544. Masonry cement shall not be used.
b) Aggregates
Aggregates shall comply with the requirements of SANS 1083, subject to all amendments and additional project requirements described in Clause
A13.4.5.2 of Chapter 13 aggregates.
c) Admixtures
Admixtures shall comply with the requirements of SANS 50934 and shall be of an approved brand and type.
d) Performance requirements for cementitious mortar or concrete
Unless otherwise specified, the cementitious mortar or concrete shall conform to the performance requirements stipulated in Table A14.4.5-1 for
class R3 for structural repairs or class R2 for non-structural repairs.
A14.4.5.3 Water
The Contractor shall prove by way of laboratory test that all water used for mixing and curing repair materials complies with SANS 51008.
A14.4.5.4 Epoxy systems

Epoxy systems shall consist of a solvent-free, two-part adhesive consisting of a resin and hardener curing at ambient temperatures. The hardener
shall be amine based with a high resistance to moisture. The epoxy shall be supplied and used in accordance with the manufacturer’s instructions
and recommendations regarding the intended use thereof. Aggregate for epoxy mortars shall be kiln-dry when mixed with the epoxy system. The
proprietary epoxy system used shall be approved by the Engineer and shall have a minimum compressive strength after 7 days of 50 MPa.
The suitability of the epoxy mortar for a particular application shall be proved by testing or submission of an approved industry track record of
usage under similar circumstances.
The epoxy mortar shall have a compressive strength equal to or greater than the adjacent concrete and it shall exhibit similar temperature
expansion characteristics. The elastic modulus, Ee, shall not exceed that of the parent concrete. Aggregate (fine and coarse) shall be clean and
dry and the size shall not exceed one third of the minimum patch thickness.
The Contractor shall be responsible for the final mix design and shall submit details to the Engineer for approval prior to its use in the permanent
works.
A14.4.5.5 Proprietary cementitious repair systems

The suitability of the repair compound for a particular application shall be proved by testing or submission of an approved industry track record of
usage under similar circumstances.
The Contractor shall submit details of the proprietary cementitious compounds to the Engineer for approval prior to its use in the permanent
works.
The repair systems shall consist of the following to be approved by the Engineer:
a) Primer for Steel Surfaces
The primer shall consist of a single component zinc rich primer as per Clause A14.4.5.7 or cementitious epoxy resin compensated three
component coating material with active corrosion inhibitor
b) Adhesion promoter for concrete surfaces
The products and measures deemed suitable for use as adhesion promoters in accordance with the proprietary repair compound and site
conditions shall conform to the requirements stipulated in Clause A14.4.5.6.
c) Concrete Repair products
For structural repairs, only Class R3 and R4 repair products conforming to EN 1504 as specified shall be used. For non-structural repairs, Class
R1, R2, or R3 repair products conforming to EN 1504 as specified shall be used.

Typical generic descriptions of suitable repair products may include:
(i) High strength, expansive cementitious grout
(ii) Free flowing structural repair concrete
(iii) Fibre reinforced, polymer modified repair mortar
(iv) High build, polymer modified repair mortar
(v) Polymer modified pore sealer
(vi) Very rapid setting repair mortar
(vii) Non-sag patching and repair mortar
d) Curing of repaired surface
The repaired surface shall be cured using a liquid membrane – forming compound as per Clause A13.4.5.9 of Chapter 13, covering with clear
polythene sheeting or water-absorbent material.
The type and application of the curing compound shall be to the Engineer’s approval.
Proprietary cementitious repair systems shall include all components and materials necessary to complete both non-structural and structural repair
of concrete structures. The proprietary repair systems shall comply with EN 1504-3. The repair system shall be suitable for the following protective
and remedial principles in accordance with EN 1504-9 as set out in Table A14.4.5-1.
(i) Applying mortar by hand (Principle 3 – Method 3.1)
(ii) Recasting concrete (Principle 3 – Method 3.2)
(iii) Adding Mortar or concrete (Principle 4 – Method 4.4)
(iv) Increasing cover to reinforcement with mortar or concrete (Principle 7 - Method 7.1)
(v) Replacing contaminated concrete (Principle 7 – Method 7.2)
The materials for proprietary cementitious repair products shall be supplied as a factory pre-packed dry premix of cements, aggregate and other
proprietary products requiring only the addition of pre-packed liquid or a prescribed volume of water of an approved quality to produce the
satisfactory repair product. The proprietary repair products shall compensate for shrinkage in both the plastic and hardened states and shall be
suitable for use in the proposed mix and placing techniques. These products are suitable for both structural and non-structural applications.
Proprietary concrete shall be highly workable and self-compacting without the use of vibrators. The aggregate grading shall be designed to prevent
segregation during transportation and placing. The concrete system shall have a low alkali content to ensure minimal risk of alkali-silica reaction and
shall contain no chlorides. The proprietary concrete shall comply with the material properties as indicated on the detail drawings, alternatively the
performance requirements defined in Table A14.4.5-1 shall apply:
Table A14.4.5-1: Performance requirements for structural and non-structural repair products
(Extract from Table 3, EN 1504-3)
Reference Requirement
Item Performance
substrate Test Method Structural Non-structural
No. Requirements
(EN 1766) Class R4 Class R3 Class R2 Class R1
1 Compressive strength None EN 12190 ≥ 45 MPa ≥ 25 MPa ≥ 15 MPa ≥ 10 MPa
2 Chloride ion content None EN 1015-17 ≤0,05% ≤0,05%
3 Adhesive bond MC(0,40) EN 1542 ≥ 2,0 MPa ≥ 1,5 MPa ≥ 0,80 MPa
Restrained shrinkage / Bond strength after test No
4 MC(0,40) EN 12617-4
expansion ≥ 2,0 MPa ≥ 1,5 MPa ≥ 0,80 MPa requirement
5 Carbonation resistance None EN 13295 Dk ≤ control concrete (MC(0,45)) No requirement
6 Elastic Modulus None EN 13412 ≥ 20 GPa ≥ 15 GPa No requirement
Bond strength after 50 cycles Visual
Thermal compatibility
7 MC(0,40) EN 13687-1 inspection after
Part 1: Freeze-thaw ≥ 2,0 MPa ≥ 1,5 MPa ≥ 0,8 MPa
50 cycles
Thermal compatability Bond strength after 30 cycles Visual
8 Part 2: Thunder MC(0,40) EN 13687-2 inspection after
≥ 2,0 MPa ≥ 1,5 MPa ≥ 0,8 MPa
shower 30 cycles
Thermal compatability Bond strength after 30 cycles Bond strength
9 MC(0,40) EN 13687-4
Part 4: Dry cycling ≥ 2,0 MPa ≥ 2,0 MPa ≥ 2,0 MPa after 30 cycles
Class I: ˃40 units wet tested Class I: ˃40 units wet tested
10 Skid resistance None EN 13036-4 Class II: ˃40 units dry tested Class II: ˃40 units dry tested
Class III: ˃55 units wet tested Class III: ˃55 units wet tested
Not required if tests 7, 8, or9 are Not required if tests 7, 8, or 9 are
Coefficient of thermal
11 None EN 1770 carried out, otherwise 9,0E- carried out, otherwise 9,0E-
expansion
6,0 mm/mm/°C. 6,0 mm/mm/°C.
No
12 Capillary absorption None EN 13057 ≤ 0,5 kg.m-2.h-0.5 ≤ 0,5 kg.m-2.h-0.5
requirement
In addition to the general occupation health and safety requirements of the works all the necessary health, safety and fire precautions stated by
the manufacturer shall be complied with.
Only material of which the shelf life has not expired shall be used.
A14.4.5.6 Adhesion promoting techniques

Adhesion of the repair material to the substrate is a priority requirement for all repair systems. Adhesion can be assisted by the use of bonding
agents, prewetting the substrate, or sealing of the substrate, as appropriate to the particular requirements of the repair system.
Bonding agents shall be supplied, pre-packaged and ready for on-site mixing and application. Typical cementitious materials may include either
a one component cementitious, polymer modified primer; or a cementitious, epoxy resin compensated three component coating material. The
Contractor shall note the limitations given by the manufacturer to pot life, workable life and open time related to the materials used.
Where appropriate to the cementitious repair system, the concrete shall be well pre-wetted but free from water on the surface at the time of
application. The surface should achieve a dark matt appearance without glistening and surface pores and pits should not contain water.
Some repair systems recommend the use of a substrate sealing compounds, this technique shall comply with the adhesion requirements of
EN 1504. Typical materials include single-component emulsion based on modified acrylic type resins, but the use of wet-to-dry type epoxy
materials shall not be permitted.
A14.4.5.7 Anti-corrosion primer for reinforcement

The anti-corrosion primer shall be a single component zinc rich primer with a minimum volume solids of 30 % complying to a 700 hour salt spray
resistance to exposure as per ASTM B-117 or a cementitious, epoxy resin compensated three component coating material with an active
corrosion inhibitor meeting the requirement of EN 1504-7.
The primer shall be supplied and used in accordance with the manufacturer’s instructions and recommendations regarding the intended
application. All necessary health, safety and fire precautions stated by the manufacturer shall be complied with.

All plant and equipment used for the preparation of concrete surfaces, batching of material and mixing operations shall be in good working order
and suited for the intended use. The plant shall be inspected, serviced and calibrated at regular intervals and tested to ensure proper functioning, all
to the satisfaction of the Engineer.

A14.4.7.1 Preparation of repair surfaces
a) Preparation of concrete contact surface
All surface laitance and damaged, loose and soft concrete, concrete containing aggressive ions e.g. chloride, as well as all foreign materials
such as oil, paint, gr

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South Africa

Standard Specifications for Road

Draft Standard (DS )

P er mis si on is gr a nt e d t o fre el y c op y, print a nd di stri but e

CHAPTER 15 – reserved for future use

CHAPTER 20: QUALITY ASSURANCE

Compiled under the auspices of the:

All rights reserved:

1.2 GENERAL REQUIREMENTS AND PROVISIONS .................................................................................................. 1-8

1.3 CONTRACTOR’S SITE ESTABLISHMENT AND GENERAL OBLIGATIONS ...................................................... 1-30

1.4 FACILITIES FOR THE ENGINEER ......................................................................................................................... 1-36

1.5 ACCOMMODATION OF TRAFFIC .......................................................................................................................... 1-50

1.6 CLEARING AND GRUBBING.................................................................................................................................. 1-70

1.7 LOADING AND HAULING ....................................................................................................................................... 1-80

PART B: LABOUR ENHANCEMENT

A1.1 GENERAL PREAMBLE

DRAFT STANDARD (DS) OCTOBER 2020 1-1

DRAFT STANDARD (DS) OCTOBER 2020 1-2

B1.1.4 DESIGN BY CONTRACTOR / PERFORMANCE BASED SYSTEMS

B1.1.6 CONSTRUCTION EQUIPMENT

B1.1.7 EXECUTION OF THE WORKS

DRAFT STANDARD (DS) OCTOBER 2020 1-3

C1.1.2.2 Measurement of completed work

C1.1.3.2 Rates to be inclusive

C1.1.3.3 Procurement, furnishing and placing material

DRAFT STANDARD (DS) OCTOBER 2020 1-5

C1.1.3.5 Payment for materials on the site

C1.1.3.6 Rate-only items

C1.1.3.7 Payment items from different Sections

C1.1.4 VARIATION FROM SPECIFIED NOMINAL RATES OF APPLICATION OR FROM

DRAFT STANDARD (DS) OCTOBER 2020 1-6

DRAFT STANDARD (DS) OCTOBER 2020 1-7

PART B: LABOUR ENHANCEMENT

A1.2 GENERAL REQUIREMENTS AND PROVISIONS

DRAFT STANDARD (DS) OCTOBER 2020 1-8

A1.2.3.3 Environmental management

DRAFT STANDARD (DS) OCTOBER 2020 1-9

A1.2.3.4 Extension of time for delays caused by rainfall

DRAFT STANDARD (DS) OCTOBER 2020 1-10

A1.2.3.5 Handing-over of the Site of the Works

DRAFT STANDARD (DS) OCTOBER 2020 1-11

A1.2.3.9 Monthly reports

A1.2.3.10 Notices, signs and advertisements

A1.2.3.11 Ordering of daywork

A1.2.3.12 Ownership of assets and disposal of non-useable assets

A1.2.3.13 Prevention of damage to nearby properties and services

DRAFT STANDARD (DS) OCTOBER 2020 1-12

A1.2.3.14 Remedial work

A1.2.3.15 Routine maintenance

A1.2.3.16 Site meetings

DRAFT STANDARD (DS) OCTOBER 2020 1-13

A1.2.3.18 Stakeholder liaison

DRAFT STANDARD (DS) OCTOBER 2020 1-14

A1.2.3.20 Road safety audits

DRAFT STANDARD (DS) OCTOBER 2020 1-15

A1.2.3.22 Wayleaves/Agreements and Permits

DRAFT STANDARD (DS) OCTOBER 2020 1-16

A1.2.4 DESIGN BY CONTRACTOR / PERFORMANCE BASED SYSTEMS

A1.2.4.3 Performance based systems

DRAFT STANDARD (DS) OCTOBER 2020 1-17

A1.2.6 CONSTRUCTION VEHICLES AND EQUIPMENT

A1.2.7 EXECUTION OF THE WORKS

DRAFT STANDARD (DS) OCTOBER 2020 1-18

DRAFT STANDARD (DS) OCTOBER 2020 1-19