A.7 ADDENDUM TO THE STANDARD SPECIFICATION FOR BRIDGE WORKSADDENDUM TO THE STANDARD SPECIFICATION FOR BRIDGE WORKS NO. 1 - GENERAL ITEMS FOR BRIDGE WORKS _ 1.1 TEMPORARY CROSSING. I.L.1 SUBMISSION FoR 8.0" APPROVAL. 1.2 BRIDGE LOADING, 13 - FACILITIES FOR TESTING... APPENDIX 1A - DECLARATION BY THE PROFESSIONAL ENGINEER ABL-2cay 12 13 ADDENDUM TO THE STANDARD SPECIFICATION FOR BRIDGE WORKS: NO. 1- GENERAL ITEMS FOR BRIDGE WORKS, ‘TEMPORARY CROSSING ‘Submission For $,0’s Approval ‘The Contractor shall propose a suitable temporary crossing to the approval of the S.O. ‘As soon as possible after the acceptance of the Tender, detailed drawings of the temporary crossing as specified in the Scope of Work required for the execution and maintenance of ‘the work shall be submited by the Contracior in triplicate lo the S.0. for approval. ‘The drawings shal be submitted with the calculation and description as necessary, in such order as will onable the 8.0. to consider simultaneously related portions of the Works. A ‘competent and experienced Professional Engineer shall and siga all submissions. All the submissions shall be declared by Professional Engineer as per Appendix LA. All dravsings shall be metrie Al size. Any work affected by the drawings shall not proceed ‘until the drawings have been approved by the $.0, No deviation from the construction procedure of temporary works, which the drawings have been approved by the S.0,, shall be permitted. ‘No approval by the S.0. of any drawings or documents submitted by the Contractor shall reliove tho Contrector of any of his responsibilities or liabilities under the Contract, and he shall be and remain entirely responsible for the proper execution, completion and maintenance of the work in accordance with the provision of the Contract. ‘The Contract Sum shell be deemed to include the cost of preparation, supply and deliver of all drawings and information, and copies thereof, which the Contractor is required to provide under the terms ofthe Contract, BRIDGE LOADING ‘The Contractor should note that the bridge bas been designed according to the loading conditions laid down in the General Layout Drawings. At the time during the construction, tho Contractor is to ensure that the bridge is not overloaded such that the pre-strossed ‘beams have tensile stresses their soffit or in-situ deck slab is loaded before having attained sufficient strength FACILITIES FOR TESTING Independent sampling and tosting will be carried out by JKR throughout the Contract period for this purpose the Contractor is to grant the use of apparatus and free access to mixing plants and storege depot, supply materials and provide all facilities for the 8.0. or his representative to sample and make tésts Whenever the S.O. so decides. ABI-LAPPENDIX 1A TEMPORARY CROSSING Dectaration by the Professional Engineer: “Thereby certify that I have designed and supervised the construction of the temporary crossing for bridge across Hee EEE _ in atccordance ith the required Toad and tn compliance with all requirements and JKR Speccations Engineer's Signature Contractor's Signature (ith official stamp and seal) (ith official stamp end seal FullName: BEerEeeeereeeee Full Name Address: ‘Address: Date:2a 22 23 24 ADDENDUM TO THE STANDARD SPECIFICATION FOR BRIDGE WORKS: NO, 2—-LAUNCHING OF PRE-CAST ELEMENTS: GENERAL. TRANSPORTATION ... GROUND PREPARATION .. ERECTION.24 22 23 24 ADDENDUM TO THE STANDARD SPECIFICATION FOR BRIDGE WORKS NO. 2~ LAUNCHING OF PRE-CAST ELEMENTS GENERAL ‘The Contractor shall inform the S.0. at least one month in advance of each launching ‘operation and submit the following to the S.0. for acceptance: (Method statement including launching system and transportation, (©) Proposal for tratfie diversion, as approprite (©) Detailed programme of each launching operation. ‘TRANS! IN ‘The Contractor shall obtain the necessary clearances for the transportation of the precast elements and movement of the lifting equipment to the Iaunching site. Contractor's ‘method of transportation shall demonstrate that the elements being transported would not be damaged. ‘A cortifcate of test of lilting equipment shall be submitted tothe S.0. together with particulars of the experiences ofthe operator. GROUND PREPARATION - ‘The ground of the launching area shall be prepared to ensure that itis safe to cam the load daring launching operation. ERECTION Utmost precautions shall be taken to eliminate any danger to the workers and general public while launching pro-cast elements, ll lifting equipment shall be designed, such that if the primary lifting mechanism fails, a secondary mechanism will ensure that the pre-cast element does not fll Upon erection, a fail-safe method shall bo used to temporarily secure the pre-cast unit ‘util the permanent fixing errangements are implemented. ‘The scouring systems, subject to the 8.0. acceptance shal include: (@) provide chain between beams and support; (©) connecting adjacent beatns by welding protruding bars of the beams or temporary bracings between the beams; (©) providing wedges or brackets to the bean. ‘The Contractor shall inform the $.O. and obiain his approval before removing any temporary work but such approval does not relieve the Contractor of his responsibilities forthe safety ofthe work ‘Tho Contractor she (®) ensure that appropriate and sufficient warning signs, lights, bamricades ond at least one rotating amber light arc placed at each point of road closure or diversion in accordance with the latest Arshan Tek (Jalan) For Temporary ‘Traffic Control.(b) © @ © © ® h) oO station at least one person in a safe postion at each point of road closure, to advise and guide motorists. The person shall be equipped with a torch, reflective vest and walkie-talkie or other mean of communications within the lunching site, have one person controlling the whole launching operation with a whistle or ‘other mean of communications with the liting equipment operators. censure that there is sufficient lighting atthe launching site, censure that no welding work on the bridge is cesried out unless a protective screen is used to prevent sparks and other materials from falling ent the areas below. install 4.5m height restriction signs of stendard design immedietely after Taunching of any pre-cast element above existing carriageway. ‘measure and record the actual height clearance ofthe bridge at every 2m along tho span ofthe bridge earriagoway. measure and record the location of the smallest clear height between the carriageway and the bridge. submit measurements showing that the height clearance of the bridge satisfies ‘tno minimum clearance to the 8.0. bofore opening the road under the bridge to teflADDENDUM TO THE STANDARD SPECIFICATION FOR BRIDGE WORKS NO, 3 - PRECAST CONCRETE SEGMENTAL WORKS BL GENERAL seonnsnns 32 GLOSARRY OF TERMS.. 3.3 PRECAST SEGMENT MANUFACTURE ‘SUBMITTALS. Cast SEOMENTS: GeoMsTRY CONTROL DORING CASTING . SBOMENT TOLERANCES, HANDLING, STORAGE AND Damage 34 PRECAST SEGMENT ERECTION WORKS.. 34.1 DESIONOF EQUIPMENT AND TEMPORARY WORKS.. 34.2. ‘TESTING OF EQUIPMENT... 7 3443. HANDLING, STORAGE AND TRANSPORTATION OF PRECAST SEOMENTS wc.cnsnarneeoe~ ABS 344 DAMAGE. 34.5 AGE OF SEOMENTS AT TIME OF ERECTION 3.4.6 ERECTIONPROCEDURE.. 34,7 ERECTION TOLERANCES. 34.8 MATCH CAST PACES von 344.9 SURFACEIN CONTACT WITH BEARING 3.5 EPOXY BONDING AGENTS FOR PRECAST SEGMENIS CONSTRUCTION . 3.5.1 MATERIALS wn 35.2 MIXING INSTALLATION OF EPOXY AND JOINTING OF SEGMENTS .. sme ABBAADDENDUM 10 THE STANDARD SPECIFICATION FOR BRIDGE WORKS NO. 3 - PRECAST CONCRETE SEGMENTAL WORKS 3a GENERAI ‘This section specifies the requirements for tho precast conerete superstructure segments inrelations to:- (@ Manufacturing, handling and storage at the precest yard, and () ‘Transporting fom the precast yard, anling, storage aud erection on site into the completed spans. (©) Theconstruction of the segments shall generally comply with requirements of the Generat andor Particular Specification except as otherwise ot additionally specified herein, 32 GLOSARRY OF TERMS “Segment” is defined as a modular section of the superstructure consisting of the cross d section and length detailed in the Contract “Match Cast" is defined as a precast conetete fabrication procedure whereby a segment is east against the preceding segment thereby producing a matching interface that pormit re-stablishment of the cast geometry at the time of erection. Match casting using the short line casting method has been assumed inthe detailing of the precast segments. short Line Casting” is defined as a method of casting segments one at a time on casting bed utilizing a fixed or moveable bulkhead. The first segment is cast between bulkheads and successive segments are cest one at a time against the bulkhead at one end and the repositioned, proviously poured, segment atthe other end. “Long Line Casting” is defined as a method of casting several concrete segments at a time on casting bed set between fixed or moveable bulkheads. “Balanced Cantilever Brector" is defined as an erection method by which segments are placed symmetically about a pier in a balanced manner, subsequently being connected to adjacent cantilevers by an in-situ stitch- "Theoretical Casting Curve" is defined as the curve of casting geometry that shall be allowed at the casting bed to achieve the theoretical profile after deformations have taken place. "Open Time" is defined as the minimum allowable period of elapsed time from the ‘pplication of the mixed epoxy bonding agent to the precast segments until the v0 segments have been assembled together and (temporarily) posttensioned, "Gel Time" is defined as the period of time the mixing bonding agent remains workable in the mixing container during, which it must be applied to the match cast joint surfaces. 33 PRE MENT FACTUI 33.1 Subunit 4) The Contractor shall submit at least 8 weeks in advance of start of casting of precast segment for the approval of tie $. complete detsils and information conceming the method, materials, equipment and provedares the Contractor proposes to use in constructing the precast segmentel works. ABBb) The submittals shall include but shall not necessarily be limited to the following information: 9 ii) it) ») vi) vi) x» xi) ‘Shop drawings giving fully and accurately dimensioned view showing the geometry of each segment including projections, ecesses, notches, ‘penings, blackouts and the like. Each segment shall be assigned an erection mark indicating its locetion and its order in the erection sequence together with such cast-in inserts, anchors and the like as may be required for the erection, Shop drawings of non-prestressed reinforcement and bar beading schedlules for each sogment inchiding such addtional reinforeement as may be required for the erection. ‘Shop drawings providing complete details ofthe fabrication systsm to bbe used including forms, foundations and geometry control Shop drawings providing theoretical casting and erection curves for cach span, accompanied by supporting calculations, so as to achieve the required alignment of the deck in is final condition. Shop drawings providing complete details of handling, storing and transporting segments including the method of lifting and stacking segments. The deteiis snail be accompanied by calculations indicating that the forces imposed during lifting and storage will not adversely affect the structural integrity ofthe segment. Shop drawings providing complete details of any additional steel reinforcement the Contractor may require in the segments to eecommodate his erection methods, transportation and banding requirements. These drawings are to be accompanied by calculations to confirm the adequacy of the additional reinforcement. Shop drawings providing complete details of any cast-in inserts, ‘anchors or box outs the Contractor may require in the segments and substructure to accommodate his erection methods, and his transportation and handling requirements. Complete details and calculations covering equipment to be used to handle segments and to incorporate thein into the structure together with a step-by-step erection procedure, stressing procedure and detalls covering the procedure for load testing of erection equipment as required herein, Details of loads, stresses and deflections to be imposed or any postion of the Permanent Works by the erection methods and equipment together with calculations demonstrating that the imposed loads will not adversely affect the structural integrity of the Permanent Works. Complete details and calculations to demonstrate that at all stages of erection and temporary stressing, the allowable stresses (zero tension) ‘ro not exceeded. The details and calculations refecred to in (vii), (ix) and (x) above shall be accompanied by Check Certificates issued by an independent Professional Engineor certifying the adequacy and safety of the proposed method and equipment. The choice of the independent Professional Engineer shall be to the approval of the 8.0. Expenses incurred in connection with this third party inspection shall be home by the Contractor. ABB -2333 ‘Cast Segments itty iy) » Ww vii) vil) The casting of segments shell not commence until the relevant submittals have been approved by the S.0. Casting beds and forms shall be made of steel and structurally adequate to support the segments without settlement or distortion. Formed surfaces of the segments shall have a Class F3 finish as described in the general Concrete Specification. articular caro shall be exercised to ensure the correct alignment ofthe tendon ducting from one unit to the next. ‘The contractor shall provide means of monitoring the accuracy of ‘manufacture and erection of the segments and of introducing any corrections found necessary as the work proceeds. The monitoring and comection systems hall be subject to the approval ofthe S.O. Each sogment shall be match cast against the previous segment in the agreed ‘erection sequence to ensure proper fit and alignment during erection, The Contractor shall provide equipment to be used to ensure the uniform separation of match cast segments, An approved bond breaking material shall be used on webs and flanges to ensure separation of segments. The adequacy of the propésed bond breaking material shall be demonstrated by a test to be approved by the S.0. Bach sogment hall be indelibly marked to show the agteod unique segment reference mark and the date on which the concrete was cast, The marking shall be located on the inside of the deck segments. Shop drawings providing as cast curves for each span accompanied by supporting calculations end records shall be submitted to the S.O. for his acceptance of the segments. ‘Geometry Control during Casting D) ») a Before commencing the casting operating the Contractor shall. submit his proposed method of geometry control of the match casting operation for the approval ofthe $.0. Geometry control procedure shall include, but not be limited to the following informatio i) The detailed narrative ofthe geometry control theory. it) The detailed narrative of the step by step geometry control procedure, iii) Detailed calculation forms and sets of sample calculations. fv) Details of proposed measuring equipment, procedures, the locations of the control points on each segment and the permanent benchmark. ‘After a segment has been cast and before bond breaking, the relative position of the two adjoining segments shail be determined from established control points. ‘This information shall then be used to determine the required alignment of the adjacent matching sezment. If the required tolerances are excooded, acceptance of the segment shall be at the discretion of the S.O. who will take into consideration the effeots of the ABS -3334 33.6 inaccuracies and whether oF not they can be compensated for the subsequent segments. The S.0,'s decision shal! be final ©) Prior to casting eny segment the Contractor shall submit details ofthe setting out tnd geometry control readings for the segment and obtain approval form the S.O. Precast segments shall be manufactured to the following tolerance: Description ‘Tolerances “Thickness of web 23mm “Thickness of top slab 23 mum “Thickness of bottom slab 23mm ‘Overall depth of segment 25mm ‘Overall widih of segment 215 mm ‘Overall length of individual segment. 210mm, ‘Overall length of 2 adjoining = 15mm segments in match cast position ‘Overall length of completo 230 maim cantilever of segment Diaphragm dimensions Zam in ent ) Forms shell remain in place until the concrete has reached a compressive strength of at least 17 N/num* unless specified otherwise in the Contract or agroed by the 80. ¥) Precast segments shall not be handled until the concrete has cached a ‘compressive strength of at least 20 N/mm? unless specified otherwise in the Contractor agrood by the $.0. ©) Transverse prestressing if required shall not be carried ont until the concrete has reached a compressive strength of at least 40 N/mm? Segments shall be lifted and supported only @ point and by methods agreed by the S.0, end shall be handled and stored in a manner to prevent torsion or other undue stress. The accumulation of trapped water and deleterious matter in the units shall be prevented. Care shall be taken to avoid staining and efflorescence, ©) The strengths quoted above are for guidance only but they are the minimum required under the Contract. The Contractor shall carry out trie, at his own cost, to demonstrate that the segments will not be damaged at the time of removing the forms or hindiing the segments with the concrete of strength and age as that proposed on site when these operations will ocow. These trials shall be completed prior to commencing casting of the segments, Damage ‘Any damage to precast segments shall be subject to assessment by the SO. The Contractor shall propose remedial measures end carry them out after the S.0.’s approval ‘has been obtained. Ifthe Contractor's proposals are unacceptable of if the 8.0 considers that repair work is unsuecessfil, the $.0 may reject the segment ABB -434 34. 342 343 3.44 34.5 PRECAST SEGMENT ERECTION WORKS ‘Design of Equipment and Temporary Works a ») °) The design of the viaduet or amp superstructure assumes erection of the segment by the balanced cantilever method. No specific provision has been made in the design of the Permanent Works for loadings imposed on any partion of the Permanent Works by erection equipment ‘other than for the loads allowed for during erection of segmonts which are: ‘Uniformly distributed toad of 0.5 50 KN point load epplied at the deck cantilever ‘The Contractor shal be solely responsible for the design, fabrication, assembly and operation ofall equipment within the loading limitations in sub-clause (b) to boused for hencling, ransporting and erecting the segments “The design of all equipment and temporary structure to be used for handling, transporting and erecting the segments inchiding the temporary prestress, props, tie-downs and anchorages required during erection of the segments shall be checked by an Independent Professional Engineer, who shall furnish @ Check Cartficate certifying the adequacy and safety of the proposed details, Testing of Fauipment Prior to the handling and erection of any segments the Contractor shall submit a method statement and perform the following tests tothe satisfaction of the S.0. ) » ‘A full scale test of ting and temporary holding hardware shall be performed to demonstrate the adequacy of this equipment. A fall scale loading test of the proposed erection girder or crane shall be performed. The girder or crane shell be supported in the same manner and using fhe same supporting devices (pier brackets, etc.) as will be used during erection cof spans. The girder shall be loeded in a manner in whic it will be usod during ‘rection of the spans with loads equivalent to 1.25 times the maximum weight of ‘the segments, Handling, Storage tai st Segments a » Segments shall be lifted end supported only at points agreed by the S.0. and shall be handled, transported and stored in & manner to prevent torsion or other wadue sess, ‘The Contractor shall transport the precast segments from the precast yard and along the site, on suitable trucks or trailer units. Damage ‘Any damage to precast segments shall be subject to assessment by the 8.0. The Contactor shall propose remedial measures and carry them out after the S.0.s approval has been obtained. Ifthe Contractor's proposals are unacceptable or ifthe S.O. considers thatthe repair work is unsuccessful, the S.O. may reject the segment. Ase of Ses ime. ion Precast segments shail not be erected until they have reached an age of 28 days unless otherwise approved by the 8.0. ‘The longitudinal post-tensioning tendons shall not be stressed until the conerete segments have atiained th specified 28 days characteristic strength. AB3-5346 347 348 349 Exection Procedure 4) Prior to the erection of each balanced cantilever, the Contractor shall provide the S.0 with setting out information for each segment showing their theoretical rected position so as to produce the required alignment on completion, faking {nto account the achieved, as-cast alignments. b) The horizontal and vertical alignment of the completed deck shall be ia accordance with the tolerances given in Clause 34.7. Ifthe deck is outside of, or likely to be outside of, the tolerance given, the Contractor shal take all measures necessary to rectify the situation to the satisfaction of the $.0., Erection Tolerances ‘The precast segments shall be etected to the following tolerances of the required alignment, determined after erection of the spant~ ©) The maximum differential between outside faces of adjacent segments in the «erected position shall not exceed 3 mma b) Across concrete-filled joints on all faces exposed in the completed structure a ‘maximum step of 3 mm, ©) Aéross all joints not exposed in the complete stracture including box interiors a ‘maximum step of 5 mn, 4) Transversely the angular deviation from the theoretical slope difference between ‘two successive segment joints shall not exceed 0,001 radians. ©) Veitically the angular deviation from the theoretical slope change between two suseessive segment joints shall not exceed 0.003 radians, 1) The difference in deck elevation at the connection of two adjacent segments (measured perpendicular to the deck surface) shall not exceed 3mam. £) The horizontal and vertical alignment of the pisr diaphragm segments measured at the centreline shall be within 5 mm of thet required by the as-cast curves. bh) In plan the contreline of each segment shall not depart from the nominal design centreline by more than 15 mm. 1) In elevation, the position of the top surface of the segments shall be such as to result in a roadway surface which complies with the Specification in respect of {hokness of asphalt wearing course, roadway Ievels and evenness of surface. Match Cast Faces Prior to erecting @ sogment, the match cast faces of that segment shall be lightly sand blasted to remove any deleterious material but without damagiag the match cast nature of the surface and such that a dry, clean surface is obtained to me approval of the S.O. ‘Surface in Contact with Bearings, ‘The concrete surface of the pier or diaphragm segment in contact with bridge bearings shall be sand blasted to the approval of me $.0, AB3-638 3.5.1 35.2 EPOXY BONDING AGENTS FOR PRECAST SEGMENTS CO) iON Materials 8) Bpoxy bonding agents for match cast joints shall’be thermosetting 100 per cea » 9 ® °° solid’ compositions thet do not contain solvent or any non-reactive organic ingrediont except for pigments required for colouring. Epoxy bonding agents shall be of two components, a resin and a hardener. The two components shall be distinctly pigmented so that nixing produces a third colour similar to the concrete in the segments to be joined and shell be packaged in per-portioned, labelled, end ready to use containers. Epoxy bonding agents shall be formulated to provide application temperature ranges that will permit erection of match cast segments at substrate temperatures fom 5°C to -S°C. If the two surfaces 10 be bonded have different substrate temperatures, the adhosive applicable to the lower temperature shall be usod. Epoxy bonding agent shall be insensitive to damp conditions during application and efter curing, snail exhibit high bonding strength to cured concrete, good ‘water resistivity low ereep characteristics and a tensile strength higher than that of the comerete. In addition, the epoxy bonding agents shall function as a Ibricant-during the joining of the match cast sogmonts, as a filer to accurately match th surface of the segments being joined, and a disable, watertight bond atthe joint. Epoxy bonding agonis shall be tested to determine their workability, gel time, ‘open time, bond and compressive strength, shear, and working temperature range. ‘The frequency of test shall bo decided by the $.0. ‘The tests shall be in accordance with appropriate ASTM standards. All instructions ofthe Manufacture and/or the formulator ofthe bonding agent shall be submitted to the 8.0. for approval. Such approval shall not relieve the ‘Contractor from his responsibilities under the Contract and the Manufacturer's instructions shell be adhered to in all aspects. xing Installation of inting of Seam ®) » 9 a 9 Joints between abutting segments shall be made using an approved epoxy ‘bonding agent as specified. Surfaces to which the epoxy material is to be ‘applied shall be fee from oil, lnitance, form release agent, or any other material that would prevent the material from bonding to the concrete surface. In addition, ‘the surface shall be dry or at least the equivalent of saturated surface dry (no visible water). ‘The level and aligument of each segment shall be checked against the previous sogment prior to application ofthe epoxy bonding agent. ‘The Contractor may make proposals, for the approval of the 8.0, for the correction of the alignment, if necessary. ‘The mixing and placing of epoxy bonding agent shall be carried out under the supervision of a suitably trained superior approved by the 8.0. Mixing shall not start until the segment is prepared for installation. Application of the mixed epoxy bonding agent shall be according to the mamufactarer's instructions using trowel, rubber glove ot brash on one or both surfaces to be joined, Tho coating shall be smooth and uniform end shall cover the entire Surface with a minimum thicknoss of 1.5 mum applied on both surfaces, or 3.0 ‘mm if applied on one surface. ‘The epoxy material shall be applied to all surfaces to be joined within the first hal of the gel time, as shown on the containers. The segments shall be joined ‘within 45 minutes aRer application of the fist epoxy material placed and = ABB -7hy % m) n) rinimum average temporary prestress of 0.2 MPa over the cross-section should be applied within 70 per cent of the open time of the epoxy material. At no point ‘of the cross-section shall the temporary prestress be Jess then 0.15 MPa. ‘The requirements in BS 5400: Part 4 (1990), Clause 73.3 shall be complied during ‘he jointing process. ‘Tho Contractor shall take all necessary measures to prevent the epoxy bonding ‘agent from coming into contaet with permanently visible concrete surfaces. ‘The Contractor shall adopt measures to prevent any of the epoxy bonding agent from entering the prestressing duct. The proposed measures shall be subuntted to the §.0. for his approval and should include sealing gaskets placed around the ‘duct holes and also precautionary roding of the duets until the epoxy bonding ‘agent has set If the jointing is not completed within 70 per cent of the open time, then the bonding agent shall be completely removed fiom surfaces. The surfaces must be prepared again and fresh epoxy shall be applied to the surface before resuming jointing operations, Hach batch of resin mixed shall be tested for setting by a shear test with lapped ‘metal strips of agreed dimensions. These shall be tested at an age of 6 hours. Should this test show mat, in the opinion of the S.0, the resin is not setting satisfactorily then the corresponding segment joint shall be broken and the resin completely cleaned off, Bach batch of epoxy bonding agent shall be tested for compressive strength using at least 3 nos. of 50 mm cubes per joint. One sample is to be tested at 24 hours, and two other samples at 48 hours. The tests shall demonstrate that compressive strengths of the epoxy bonding agent have echieved 20 MPa at 24 hours and 55 MPaat 48 hours. ach batch of epoxy bonding agent shall be tested for bonding strength using at least 3 nos. of samples per joint. Bach testing sample shall consist of 2 nos. of 150 mm x 150 mm x 225 mm concrete prisias with compressive strength of 55 MPa at 28 days, joining together on the properly prepared 150 mm x 150 mm face with the epoxy bonding agent. The tests shall be conducted at 24 hours using the Standard ASTM C 728 test for flexure strength. A. companion test beam shall be prepared for the same concrete, cured for the same period, and tested following ASTM C 78. The epoxy bonding agent is acceptable if the load on the prisws at failure is greater then 90 per cent ofthe load on the reference test beam at feilure, ‘A record sheet on an approved form shall be prepared for each joint. This shall Joint reference Date and time of jointing Ambient temperature Weather conditions Epoxy resin formulation Batch numbers Numer and quantity of mixes Observed gel time of the epoxy bonding agent Surface conditions of the segments being joined {All personnel using epoxy resin shall be notified in writing about the dangers of skin contact and shall be supplied with suitable protective coating. Chemicals for {he removal of epoxy resin shall be evalable in a clearly marked box sitvated within 10 m of the place of mixing and/or placing, AB3-8ADDENDUM TO THE STANDARD SPECIFICATION FOR BRIDGE WORKS: NO. 4—BLENDED SHREDDED TIRES 4.1 INTRODUCTION... 42 MATERIAL PROCESSING REQUIREMENT. 42.1 SHREDDING. conn eeanenaeaies 43. ENGINEERING PROPERTIE! 43.1 PARTICLE SIZE AND SHAPE, 43.2 SPBCIFIC GRAVITY... 43.3 Conmpacten Uni WetoHr., 4.3.4 SHEAR STRENGTR.. 43.5 COMPRESSIBILITY... 43.6 PERMEABILITY nn 43.7 COMBUSTIBILITY 4.4 DESIGN CONSIDERATIONS. 44.1 MIKDESIN. 45 CONSTRUCTION PROCEDURES... 4.5.1 MATERIAL HANDLING 4.5.2 SITBPREPARATION 853 MIKING scnrnonennre 4.5.4 PLACING AND COMPACTION ABE4a 42 421 43 431 ADDENDUM TO THE STANDARD SPECIFICATION FOR BRIDGE WORKS NO. 4 BLENDED SHREDDED TIRES Introduction, Discarded vehicle tyres aro traditionally disposed of as waste materials, largely into Jandfills or tyre stockpile sites where they can pose potential safety and health problems, as ‘well as being unsightly. In recent years, however, interest has been shown in the use of serap tyres as feedstock for recycled or reused materials. This has included highway engineering applications including pavements, soil reinforcement and drainage materials, ‘The use of tyze skreds for the construction of embankments provides @ number of advantages. The most obvious advantage is that of reduced unit weight, which is especially beneficial in situations where an embankment is to be constructed over an area with low bearing support. In addition to being a lightwoight fll material, tyre shreds havo good drainage characteristics, being as permeable as @ coaise gramular soil. Embankments present an excelleat opportunity to utilize large volumes of scrap tyres from one location fand, under the proper logistical circumstances, can be a very economical altemative to {ported earth borrow. ‘Matertal Processing Requirement Shredding ‘The size and shape of tyre shreds from tyre shredding can vary depending on the type of shredding machinery used. Tyre shreds have a wide range of sizes, from 75 mm up to 300 rm, wich is ordinarily the largest size recommended. Usually, tyre shreds ace inregulsr i shape with the smaller dimension being the size specified by the manufacturer and the larger dimension possibly being two or more times as much, Same shreds may have pieces of steel belt exposed along the edges. “To minimize potential compaction problems (Le, to reduce void space) it may be desirable to use smaller size tyre chips of 50 mm or less. Tyre shreds shall be free of contaminants such as oil, grease, gasoline, diesel fie et, that could create fire hazards. Metal fragments that are patilly encased in rubber shall protrude no more than 25 mm fiom the cut edge of ‘the tyre shreds, on approximately 75% of the piece and no moro than 50 mm on 100% of the piece, Engineering properties article Size and Shape ‘Tyre shreds are well-graded, usually ranging from 100 mm to 200 mm in size. Some particles may be 300 mm or even larger, including some strip-shaped pieces. The most ‘unusual properties of tyre shreds are their flat and somewhat irregular perticle shape and thoir relatively low unit weight. The flat shreds, especially the larger sizes, tend to lay on top of one another and develop some degree of particle interlock. They also tend to be ‘oriented parallel to the horizontal sheer plane, Particle size distribution can be determined by performing a standard sieve analysis using the procedures of ASTM D422. No modification ofthe standard test method! is required, except that tyre shreds larger than 75 ‘mm cannot be soreened through standard sieves. A limited amount of geotechnical analysis has been performed on different sizes of tyre chips. Grain size enalyses have indicated that the tyre shreds can be classified as a well- graded, coarse-grained material, similar to an A-L-b sand and grevel (AASHTO ML45) or as an SW well-graded send with gravel (ASTM D2487). ABA-1433 434 435 ‘Specific Gravity ‘The specific gravity of tyre shreds is expected to be in the 1.1 to 1.3 range, with higher specific gravity values for shreds containing steel belts. ‘Compacted Unit Weight Depending onthe size ofthe tyre shreds, compacted unit weights can range from as low as 322 kg/m’ to as high as 725 kg/m’, Tyre shreds have a maximum density that is pproximately one- third to one-fourth that of typical earthen fill material. The cosrsor the size of the serap tyre particle, the lower the compacted unit weight. Determination of compacted density of air-dried tyre chips is bes! made by an adaptation of ASTM D1557 (Modified Proctor test). A 254 mm diameter by 254 mm high mold is recommended {instead of the usual 100 mm diameter high mold. Since the level of energy applied is not tical, 60 percent of standard Proctor compaction offort is recommenced. Shear Strength Limited direct shear testing of tyre shreds has been performed using @ specially made large-scale direct shear testing apparatus, The fiction angle of tyre shreds from these tests ranged from 19° to 25°. Cohesion values range from 7.6 N/mm’ to 11 .5 Némm, although significant deformation was required to develop cohesion, ‘Tyre shreds with a greater amount of exposed sice! beits tend to have a higher angle of internal friction. Typical granular soils have friction angles between 30° and 40° with little ‘apparent cohesion. “The shear strength of tyre shreds can be evaluated by performing direct shear fess using @ 305 mm square shear box. This is a modification of ASTM D3080 and is applicable to the ‘esting of 75 mm maximam size tyre shreds, ‘Tyre shreds are much more compressible during the initial stages of loading than cojventional soils. Subsequent loading cycles normally result in significantly less compressibility ofthe tyre shreds. Higher amounts of exposed steel belts appear to result in higher compressibility, especially during the first loading cycle, probably because of less rebound. ‘Compressibility analysis of tyre chips indicates that the Young's modulus of tyre shreds is 2 to 3 orders of magnitude less than tao modulus of granular soil. The values of Young's modulus for tyre chips range from 770 N/mm? to 1250 Nim”, Therefore, at least 1 Om of conventional soil is required to be placed on top of a layer of tyre shreds in order to prevent or minimize surface deflections, Compressibility can be analysed by applying a vertical load to cormpacted tyre chips (5 layers, 60% of standard Proctor effort) within a 305 mm diameter by 305 mm long, schedule 40 PVC pipe equipped with horizontal and vertical strain gauges. The strain gauges record horizontal and vertical stress and strain readings at 10 second intervals Readings are plotted on stress-strain curves. The slopes of these curves are indicative of ‘the compressibility of tyre shreds and the coefficient of lateral earth pressures.43.6 437 44 44d 45 45.1 432 453 Permeability. ‘The coefficient of permeability of tyre shreds was found to range from 1.5 to 15 onvsee, Aepending on their void ratio. This is equivalent to the permeability ofa clean gravel sol Permeability testing can be accomplished using a 305 mm diameter by 960 mm long PVC pipe and following the constant head testing procedures of the Califomia Department of ‘Transportation, A 38 mm diameter water inlet was fixed to the contre ofthe end cap. A 101 rm wide by 50 mm deep slot was cut into the top of the PVC pipe to allow water 10 flow oat the top of the apparatus. The intial length of the tyre shreds sample is about 600 mm. Combustibility Although sorap tyre patticles are not in and of themselves capable of spontane combustion, it does appear to be possible that, undor certain circumstances, an initial exothermic reaction may occur within a tyre shred embankment or backfill that comld ‘eventually relse the temperature within the fill to a point where ignition could possibly cou, ‘Design Considerations Desi ‘Tyre sheds can be mixed or blended with sand, As the percentage of sand is increased, the unit weight of the blend increases. To simplify blending inthe field, mix ratios are usually propared on a volumetric basis, A 50:50 tyre shreds to sand ratio is suggested so that tyre shred usage is not reduced too greatly. Sand shall have a gradation conforming to the envelope shown in Table 2.1 of Section 2—Karthworks: Standard Specifications Construction Procedures Maria Handling At the tyre processing facility, the number of tyres to be processed into shreds is directly related to the intended volume of the tyre shred portion of the embankment. I is estimated that every cubic yard of volume will require about 75 automobile tyres that have been shredded into shreds and compacted into an embankment, ‘Site Preparation ‘The site of the embankment should be prepared in essentially the same manner as though suitable materials were being used for fill material. If there is a bigh water table or swampy area that will be at the base of the embankment, it may be advisable to construct a drainage blanket. If there is a natural flow of runoff through the area waere the embankment is to be constructed, provisions should be made to pipe the runoff beneath the embankment. ns ‘When tyre shreds are to be blended or mixed with sand, the mixing should be performed volumetrically, using bucket loads ftom a front end loader and blending the materials together es well as possible with the bucket. As another option to tho mixing of tyre shreds and sand, alterate layers of the tyre shreds and the sand can be constructed.4SA Placing and Compaction ‘Tyre shreds may be spread across with a minimum 0.5 m layer or lit. A recommended maximum 1 m lift thickness can still be spread and compacted. Compection may be achioved by at least three passes of the 1800 kg vibrating plate or equivalent over the layer of tyre shreds. ‘The shred particles align themselves with each other and settle fairly readily. For larger shreds or thicker layors of shreds, as many as 15 passes of a vibrating plate may be required to achieve compaction. Once the vibrating plate is able to pass over a layer of tyre shreds with litle to no noticeable deflection or movement, the next layer or lift of tyre shreds can be placod, There is really no practical method at this time for performing an in-place density test on a layer of compacted tyre shreds. The best way to ensure that the layer has been sufficiently compacted before placement of the next layer is to continue passes of the vibrating plate over the tyre shreds until there is no more ‘movement of the tyre chips when the bulldozer passes over thera. The top layer of a tyre shred embankment should be kept at cast 1.0 m below the base or subbase layer of the pavement that will be on top of the embankment. Bach layer of a tyre shred embankment ‘must be fully compacted before the next layer is placed, At least 0.6 m of soil should also be placed on the side slopes of the embankment to cover the tyre shred. The soil on the slopes should be compacted to the extent possible, covered with topsoil, and seeded to establish erosion control protection. The additional soil cover on the side slopes will also help minimize the potential of exothermic reactions occurring within the scrap tyre ‘embankment. ABA-4ADDENDUM TO THE STANDARD SPECIFICATION FOR BRIDGE WORKS NO, 5 - MISCELLANEOUS FOR BRIDGE WORKS: 5.1 HANDRAILS. 5.1 GENERAL, 51.2 HANDRAIL AND POST ERECTION. 53° PAINTING. eu 52 BRASS PLAQUE. 52.1 DESCRIPTION. 522 MATERIAL. nn 52.3 FABRICATION. 52.4 INSTALLATION... 53 PROTECTIVE COATING SYSTEM wen. 53.1 SURFACE PREPARATION : 53.2 __ COATING MATERIALS TO Dick Sort, RC. DIAPHRAGMS, CAPPING BEAMS, BTC 5.3.2.1 Material Properties . 33.2.2 Application... $3.3 COATING MATERIALS TO ALL ABUTMENTS AND PIERS wens 533.1 Material Properties . 533.2 Application nnn 54 GABION MATTRESS. SA.1 — DESCRETION. 55 GEOTEXTILE FABRIC... 55.1 DESCRTION..ADDENDUM TO THE STANDARD SPECIFICATION FOR BRIDGE WORKS NO. 5 - MISCELLANEOUS FOR BRIDGE WORKS 5A HANDRAILS SAL General Hiandcails for bridges shall be galvanised iron sections as detailed in the Drawings. They shall be fabricated accurately to the dimensions shown on the Drawings and shall be rected true to line and level ‘The post shall be fabricated to the details shown on the Drawings and shall be galvanised. S12 Handrail And Post Hrection ‘The handrail post shall be fixed as detailed in the Drawings All items of steel and ironwork for the handrails shell receive two flat under-coats followed by one high gloss finishing coat of ensmel paint all lo the approval of the S.0. ‘Two coats of bituminous paint shal be applied to the base of each post “The Contractor shall be deemed to have included the cost for painting in the rates forthe nals, $82 BRASS PLAQUE 52.1 scription ‘This work shall consist the supply, fabrication and instalation of brass plaque. The work shail be carried out all in accordance with this specification and the shape and dimensions shown in the Drawings and as directed by the S.0. 922 1 ‘The material for the plaque shall be yellow brass alloy designation SCB 6 as specified in BS 1400. 523 Eabrication ‘The plaque shall he of size 420mm x 297mg x 3.2mm thick and shall be free from any damage and defect, The background shall be of a dark oxidized finished. ‘The letters and numbers shall be 1.5mm thick and shall be spaced at 1.Smm apart, The letters, numbers, JKR logo, etc. are to be of size 28 shown on the drawing and stall be welded to the brass plaque. They shell be thoroughly cleaned and polished to give shinny finished. A protective clear coating shall be applied to the brass plaque.524 53 $34 53.2 532.1 Installation ‘The brass plaque shall be laid on to a 440mm x 317mm x Simm thick epoxy mortar bedding and glued together using epoxy glue, ‘The brass plaque shall be fixed at the parapet, wingwalls or the outor face of the edge beam using 5.0mm diameter flat head screw embedded to « depth of SOmm. An oval brass cap shall be fixed on top of all setews. PROTECTIVE COATING SYSTEM ‘Surface Preperation Prior to application all surfaces must be dry and free ftom oil, grease, loose particles, decayed matter, moss or algal growth and general curing compounds. All such contamination anc laitance must be removed by the use of grit blasting, high pressure ‘ater jetting or equivalent mechanical means. Before proceeding to apply the protective coatings, all surfaces which are not to be coated but which may be affected by the application ofthe coating shall be fully masked ‘and in particular, flora/fauna shall be protected. Blow holes and areas of pitting shell be mado good with a one pan modified cementitious material, and allowed to cured in accordance with the manufacturer's recommendations. The application shall be in accordance with the manufecturer's recommendations, particularly with respect to the maximum application thickness of 3inin, Fresh concrete shall be at least 28 days old before receiving surface preparation. ating Materials To Deck Soffit, R.C. cx Ete. ‘Material Properties “The protective coating shall consist of a duel protective e system formed by two coats of silene-siloxane based primer and two coats of solvent besed methaerylate pigmented top coat. ‘The Contractor is required to adhere strictly to the manufacturer's recommendations regarding the use, storage, application and safety rules in respect of the approved materials, ‘The coating shall be applied by spray, roller or brush 10 achieve @ finish acceptable to ‘he $.0. In all operations of storage, mixing and application the Contractor is comply with the Health and Safety recommendations of the manufacturer and. governing authorities. ‘Where required by the $.O. trial area not exposed in the finished work shall first be treated using the selected materials. These trial areas shall be noted on the drawings and shall be carried out using thé type of materials, mixing procedures and pplications tbat will be used on the Contract and shall be approved by the $.0. before Contractor ‘commences with the general work. ‘The material employed for the coating shall comply with the following requirement or equivalent:-53.22 533 $331 ) Wet film thickness 150 microns per coat ») Dryfilm thickness 175 microns per coat ©) Reduction in water absorption (asTM C642) 80% minimum @ 28 days 4) Carbon Dioxide diffusion resistance (Research Laboratories Tywood ee Engineering Lt) Casubalasent ©) Water vapour transinission (Research Laboratories Tywood Shall be more than 13 g/m*/éay “Engineering Lt.) 1 Reduction in chloride ion penetration 90% minimum @ 28 days ® Gemacen sealing ‘Unaffected by 50 exposure cycles Notes: Where test methods are not specified, the procedure for establishing compliance with the above citaia shal be agreed by the S.0. Application Primer shall he applied in at least two flood coats using a low pressure Knapsacle sprayer, Application shall be reposted until correct coverage is achieved. On very porous surfaces application shall be repeated until surface is completely saturated. All treated surfaces shall be allowed to dry for at least 2 hours When the surface is visibly dry, the Topcoat shall be applied. Ifthe surface is porous, it shall be stabilised by a coat of the appropriate grade diluted with 5% of an approved solvent. ‘A two ovat, pinhole free application of the Topeoat shall be applied. Four hours drying ‘between coats shail be allowed, Coating Materi I Abutments And Piers Material Properties “The solvent free based epoxy resin coating shall comply to the following propertos:- 8) Specific Gravity : 1.67 (epprox.) +) Volume Solids + 100% ©) Recommended thickness per coat: dry film thickness (dft) 200 jam wet film thickness 200 mm ) Theoretical Coverage : Sint (3m7/kg) fora dA of 200 pm533.2 54 SAL 55 55.1 ©) Practical Coverage : ‘Theoretical coverage is quoted for guidance. Practical coverage may be lower depending on sub-state and application method. 4) Numbers of Coats : 2 8) Pot Life: ‘At20°C ‘At30°C 30-40 minutes —12~20 minutes 4) Drying Timo: ai20°C 30°C Touch Dry hours 3 hours Fully Dry, 7 days 7 days Recoatable 6=24hous ——-3— 12 hours 4) Application Temperature : Minimum 5° JD) Resistance of Film: ‘The fully cured coat is resistance Distilled Water Chlorinated Water Brine 20% Marsh Water Sewerage Water Gas Oil” Kerosene Sea Water ‘Sodium Hydroxide 10% Porrol* (©) May cause surface discolouration Application Brash shall be used end the first cost must be firmly applied and be well scrubbed into the surface and a continuous costing of uniform thickness shall be ensured. The second coat shall be applied 6 ~24 hours later. GABION MATTRESS Description ‘This work shall consist of the construction of miscellaneous erosion protection and to be composed of stone filled wire mesh mattress. The work shall be carried out all in accordance with the Specification and as shown on the Drawings and/or as approved by the 8.0. For more dotails about Specification for gabion mattress, please refer to ‘Addendum Specification to Section 3: Drainage Works. GEOTEXTILE FABRIC Description ‘The geotextile fabric shall meet or exceed the following requirement in full Product not meeting these requirements shall not be accepted. The work shall be carried out all in accordance with the Specification and as showm on the Drawings and/or as approved by the S.O. For more details about Specification for geotextile fabric, please refer to Section 20: Geotechnical Works. ABS -4