Part 7 – Paving

Table of Contents
PAGE

7 Paving ............................................................................................................................ 1
Scope of Works ........................................................................................................ 1
Description ......................................................................................................... 1
Standards ................................................................................................................. 1
Unbound Pavements ................................................................................................ 2
Material .............................................................................................................. 2
Materials Testing ................................................................................................ 5
Construction ....................................................................................................... 5
Geometric Tolerance.......................................................................................... 8
Acceptance Testing............................................................................................ 8
Cement Bound Material (CBM)................................................................................. 8
Material .............................................................................................................. 8
Cover Material ...................................................................................................10
Bedding Sand ..........................................................................................................10
Concrete Blocks ......................................................................................................12
Jointing Sand ..........................................................................................................13
Bitumen ...................................................................................................................15
Material .............................................................................................................15
Testing ..............................................................................................................15
Information to be Provided by the Contractor ....................................................16
Maximum Reduction in Standards.....................................................................16
Bitumen Emulsion ...................................................................................................16
Material .............................................................................................................16
Emulsion Properties ..........................................................................................17
Testing ..............................................................................................................17
Bitumen Cutter and Flux Oils ...................................................................................19
Material ..........................................................................................................19
Properties ......................................................................................................19
Properties of Bitumen Cutter and Flux Oils ....................................................19
Medium Curing Cutback Bitumen ............................................................................20
Material ..........................................................................................................20
Properties ......................................................................................................20
Temperature of Supply...................................................................................21
Testing ...........................................................................................................21
Pavement Prime ......................................................................................................22
Material ..........................................................................................................22
Surface Preparation .......................................................................................22
Spraying ........................................................................................................22
Method of Application ....................................................................................22
Spray Rate .....................................................................................................23
Other Pavement Types............................................................................................23
7 Paving
Scope of Works

Description

This Section of the Specification covers materials, design, supply, construction and
testing of the concrete block pavement. Immediately prior to pavement placement,
the subgrade shall have been prepared in accordance with Section 5 – Earthworks.

The design shall be in accordance with Interpave’s “The Structural Design of Heavy
Duty Pavements for Ports and Other Industries, 4th Ed”

Block pavement comprises:

i) 100mm x 200mm x 120mm concrete blocks (50 MPa) overlying

ii) 30 mm bedding sand overlying

iii) Curing layer and a 5mm bitumen emulsion seal overlying

iv) Cement Bound Material as shown on the drawings overlying

v) 150mm Dense Graded Crushed Rock (min compaction of 95% MDD)

overlying

vi) Tensar SS20 Geogrid or Equivalent

The concrete block course is completed by the installation of jointing sand into the
block vertical joints and application of an epoxy joint sealant.

The frequency of testing for all stages shall be sufficient to ensure that the results
obtained from any test are completely representative of the materials or work being
tested. The exact number of tests will normally be determined on Site and agreed
with the Engineer, unless otherwise stated in the specifications.

The Contractor and/or the paving Subcontractor shall demonstrate prior and
satisfactory experience in this type of work.

No works shall commence until the pavement sub-grade has demonstrated

compliance with the requirements of Section 5 and this specification.

The Contractor shall submit proposed details for drainage of the bedding sand.

Standards

All materials, workmanship and testing shall comply with the relevant Clauses of this
Specification, and with the relevant requirements of any of the current issue of the
following Codes and Standards, or the equivalent British Standard, as agreed by the
Engineer:

a) American Society for Testing and Materials (ASTM) Publications

C 29 Unit Weight and Voids in Aggregate

C 117 Materials Finer Than No 200 (75µm) Sieve in Mineral

Aggregates by Washing

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 C 131 Resistance to Degradation of Small Size Coarse Aggregate by
Abrasion and Impact in the Los Angeles Machine.

C 136 Sieve Analysis of Fine and Coarse Aggregates

D 1140 Amount of Material in Soil Finer than No 200 (75µm) Sieve

D 1556 Density of Soil in Place by the Sand-Cone Method

D 1557 Moisture Density Relations of Soils and Soil-Aggregate Mixtures

Using 10 lb (4.54 kg.) Rammer and 18 in (457 mm) Drop

D 2487 Classification of Soils for Engineering Purposes

D 2922 Density of Soil and Soil-Aggregate in Place by Nuclear Methods

(Shallow Depth)

D 2217 Wet Preparation of Soil Samples for Particles Size Analysis and
Determination of Soil Contents

D 3017 Moisture Content of Soil and Soil-Aggregate in Place by Nuclear

Methods (Shallow Depth)

D 4318 Liquid Limit, Plastic Limit, and Plasticity Index of Soils

D 2419 Sand Equivalent Value of Soils and Fine Aggregate

D 4253 Maximum Index Density of Soils Using a Vibratory Table

D 4254 Minimum Index Density of Soils and Calculation of Relative

Density

D 75 Sampling Aggregates

D 1883 Bearing Ratio of Laboratory-Compacted Soils

b) American Association of State Highway and Transportation Officials

(AASHTO).

M 147-65 Materials for Aggregate and Soil-Aggregate Subbase, Base and

Surface Courses

c) Interpave Manual

The Structural Design of Heavy Duty Pavements for Ports and Other
Industries, 4th Ed

If any matter is not referenced in any of the above documents then an internationally
recognised Standard shall be agreed with the Engineer and used.

Unbound Pavements

Material

1) Dense Graded Crushed Stone Material

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 The course coarse component shall be graded crushed aggregate consisting of
durable and sound crushed gravel or crushed stone and shall be free of lumps or
balls of clay or from flat elongated, soft or disintegrated pieces of organic matter,
sulphide minerals and other deleterious materials.

The fines component, that portion of material passing the No. 40 sieve, shall be of
such composition that the composite material conforms to the requirements specified
herein. It shall be of such nature that it can be compacted readily with watering and
rolling to a firm, stable base.

Material supplied shall be provided with a material source assessment and include
an investigation of geological site characteristics and source material properties.
The assessment shall indicate the presence of materials with properties superior to
the standard specified, and shall be forwarded to the Engineer at least ten working
days prior to material delivery to Site.

Materials shall comply with the additional requirements listed below:

- Crushed Gravel retention on a No. 4 Sieve

90% min. by weight with at least two fractured faces

100% min. by weight with at least one fractured face

- Grain size shall be determined in accordance with ASTM C 136

- Aggregate wear 45 max when tested in accordance with ASTM C 131,

Grading A

- Material passing the No. 40 Sieve:

Liquid limit 25 max in accordance with ASTM D 4318

Plasticity Index of 5 max in accordance with ASTM D 4318

- Samples shall be prepared in accordance with ASTM D 2217,

Procedure A

- Material California Bearing Ratio of at least 80% as determined by

laboratory tests on a 4 day soaked specimen in accordance with ASTM
D 1883

- Material compaction in accordance with ASTM D 1557 Method D

- Aggregate shall conform to one of the sizes listed in the table below:

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 Table 10.1

Percentage by Weight Passing

Square Mesh Laboratory Sieves

Sieve 1 2 3

5 cm 100 - -

3.75 cm 70-100 100 -

2.5 cm 45-80 60-100 100

1.25 cm 30-60 30-65 40-70

No 4 20-50 20-50 20-50

No 10 15-40 15-40 15-40

No 40 2-25 5-25 5-25

No 200 0-10 0-10 0-10

2) Crushed Stone Sub-Base Course Material

This material shall meet the same requirements as for the Dense Graded Crushed
Stone Material above.

3) Geotextiles.

Geotextiles material properties, testing, and placement shall meet the requirements
of Section 5 of this Specification,

4) Select Fill

Select fill shall be free from soluble salts, organic matter, clay and other deleterious
matter.

Material excluding sand shall be gravel or loam and shall have material properties
as specified below.

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 Table 10.2

Gravel and Loam Material Properties

Percentage (by mass)

AS Sieve Size Passing Sieve

(mm)

Gravel * Loam

37.5 100 100

9.5 60 - 85 100

2.36 25 - 70 70 - 100

0.60 15 - 50 15 - 50

0.075 3 - 30 3 - 30

Other Properties

Linear Shrinkage 8 max. 6 max.

* Material of size greater than 2.36 mm shall be rock.

Materials Testing

Testing shall be carried out in accordance with the requirements of this Specification.

The Contractor shall obtain and forward to the Engineer for approval, prior to delivery
of any material, test reports giving details of grading, bearing ratio, Atterberg limits
and optimum moisture content.

Water content shall be continually laboratory monitored and maintained at the

predetermined laboratory optimum moisture content. One field density test shall be
taken for every 250 tonnes or 500 m2 of layer (whichever gives the highest number)
of material placed, but not less than one random sample per days run or one random
sample per batch. The Engineer may direct such further field density tests as he
may consider necessary. Field density tests shall be in accordance with ASTM D
1556 or ASTM D 2922 and ASTM D 3017.

Note: Sand bedding shall not be used as a filler to correct base course profile.

Construction

The dense graded crushed rock base course material when placed shall be well
graded and placed in layers of thickness (loose) between 150 and 250 mm. Under
depth areas shall be scarified before addition of material, re-blading, re-conditioning
and recompacting.

Select fill shall be at least 95% of the maximum density determined in accordance
with ASTM D 1557. The dense graded crushed rock base course material shall be
compacted to at least 95% of the maximum density, and dense graded crushed stone
sub-base shall be compacted to at least 95% of the maximum density determined in
accordance with ASTM D1557.

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 The final unbound material layer shall have a uniform surface free from loose,
segregated and contaminated areas and the coarse particles shall be slightly
exposed. This may be achieved if the surface is trimmed, lightly watered, drag-
broomed and rolled.

The Contractor shall use the most appropriate item of equipment shown in the table
below to obtain the level of compaction required. Variations will be permitted if the
Contractor can demonstrate that the compaction achieves the specified
requirements.

Table 10.3

Passes for Compaction

Number of passes for layers not

exceeding the following compacted
Type of compaction
Category thickness:
equipment
110 mm 150 mm 225 mm

Smooth-wheeled Mass per metre width of roll: - - -

roller (or Vibratory
Over 2700kg up to 5400kg 16 Unsuitable Unsuitable
roller operating
without vibration) Over 5400kg 8 16 Unsuitable

Mass per wheel: - - -

Over 4000kg up to 6000kg 12 Unsuitable Unsuitable

Pneumatic-tyred roller Over 6000kg up to 8000kg 12 Unsuitable Unsuitable

Over 8000kg up to 12000kg 10 16 Unsuitable

Over 12000kg 8 12 Unsuitable

Mass per metre width of

Vibratory roller - - -
vibrating roll:

Over 700kg up to 1300kg 16 Unsuitable Unsuitable

Over 1300kg up to 1800kg 6 16 Unsuitable

Over 1800kg up to 2300kg 4 6 10

Over 2300kg up to 2900kg 3 5 9

Over 2900kg up to 3600kg 3 5 8

Over 3600kg up to 4300kg 2 4 7

Over 4300kg up to 5000kg 2 4 6

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 Over 5000kg 2 3 5

Vibrating plate Mass per square metre of

- - -
compactor base plate:

Over 1400kg up to 1800kg 8 Unsuitable Unsuitable

Over 1800kg up to 2100kg 5 8 Unsuitable

Over 2100kg 3 6 10

Vibro-tamper Mass: - - -

Over 50kg up to 65kg 4 8 Unsuitable

Over 65kg up to 75kg 3 6 10

Over 75kg 2 4 8

Power rammer Mass: - - -

100kg – 500kg 5 8 Unsuitable

Over 500kg 5 8 12

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 Geometric Tolerance

Geometric tolerances are defined in the below table;

Vertical -0

+ 15 mm (in the direction which increases the

thickness of the pavement)

Horizontal - 50 mm

+ 250 mm (in the direction which increases the width

of the pavement)

Deviation from a

straight edge on the 5 mm in 3 m.

surface of a layer

Cross fall 10mm measured between any two points 2 m apart

(difference from theoretical level)

Acceptance Testing

Testing of placed material shall be at a frequency of one test for every 250 tonnes or
400 m2 of layer (whichever gives the highest number). The tests undertaken shall
be;

a) MDD – to meet requirements of Cl 10.3.3 above,

Cement Bound Material (CBM)

Cement bound pavements shall be constructed using a plant-mixed pavement

material which comprises a mixture of unbound pavement material in accordance
with Cl 10.3 and a hydraulic stabilising agent.

Material

Stabilising Agent: Cement Type I in accordance with ASTM C 150, or blended

stabilisation agents as approved by the Engineer.

Curing Agent for

the final layer: Bitumen emulsion in accordance with this Specification

Cover Material: Clean sand in accordance with this Specification for block
pavement - Bedding sand.

Pavement Material: Base course material (compaction of 95% MDD) in

accordance with this Specification. After treatment with
stabilising agent, the material shall achieve the values of
strength and plasticity referred to below:

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 Plasticity: Design Strength (after treatment)

Minimum As shown on drawing

Maximum 5 MPa above minimum

Maximum Shrinkage of 250 micron

The addition of approximately 4-5 % by mass of stabilising agent to the base course
material should achieve the values set out above. However, the exact amount must
be determined by laboratory tests which the Contractor shall carry out.

The testing procedure to determine the optimum amount of cement to be used shall
be as follows. Trial batches of the approved base course shall be prepared with
cement contents of 3 %, 5 % and 7 % by weight. For each batch, replicate specimens
for unconfined compression testing shall be prepared using modified compaction as
specified. The characteristic unconfined compression strength shall be determined
after 7 days accelerated moist curing for each batch, or 28 day strength. Shrinkage
shall be tested at 28 days.

The mixing procedure for the course and stabilising agent shall be submitted to the
Engineer twenty working days prior to commencement. The procedure shall list how
the Contractor proposes to perform the following functions:

- mixing

- delivery of mixture

- paving

- compaction

- preparation of the edges and surfaces

- moist curing

- application of the curing and cover coats

The mixing equipment shall be capable of producing pavement material complying

with the Specification and of a sufficient rate to meet the Contractor's placing rate.
The maximum standard deviation of stabilising agent content shall be 0.3 %.

At the time of mixing, the percentage of water in the mix shall be the amount that
ensures a uniform and intimate mixture of aggregate and cement during mixing. In
no case shall the moisture content exceed the optimum moisture content for
compaction.

Upon delivery to Site, the stabilised course material shall be spread, compacted and
trimmed within an elapsed time of not more than three (3) hours from the time of mixing.
Any stabilised course material has been delivered to Site shall not remain undisturbed
for more than thirty minutes.

If the adjoining layer is not placed within the two hour period, the edge of the existing
layer shall be cut back 150 mm min. The existing layer edge shall then be treated at a
rate of 2 kg/m with cement in the form of a cement/water slurry which has a
water/cement ratio between 0.6 min and 0.7 max. When compacting the fresh mix

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 against the face of the existing layer, the roller shall be partly supported on the
previously compacted layer.

Layers other than the final layer shall be moist cured by maintaining the layer surface
and edges in a continuously damp condition, using a fine spray for seven days or until
that particular layer is covered by the next layer whichever comes first.

Compaction shall be to not less than 95% of maximum dry density with the pavement
material having a maximum shrinkage of 250 micron at 28 days.

Where the thickness of the cemented layer is greater than 200 mm (compacted) it shall
be placed in more than one lift. The various layers shall be bonded together by either:

• Using a retarder in the lower layer and placing the second layer within 3 hrs
of placing the first layer, or

• Allow the first layer to cure for a minimum of seven days. Prior to placing
the second layer the first layer shall be covered with cement slurry at a rate
of 2 kg. of cement per square meter at a water:cement ratio of 0.6-0.7.

After compaction and final trimming, the course shall be primed by a light application
of bituminous emulsion, or such other application as may be required by the
Engineer. The curing operation of the final layer shall commence no later than 30
minutes after the completion of compaction. If the curing membrane cannot be
placed the layer shall be moist cured until the membrane is placed.

The prime serves as a curing membrane on the cement-stabilised course. The rate
of application should be just sufficient to ensure a thin continuous waterproof
membrane is applied over the course without substantial penetration of bitumen into
the material. This curing treatment is separate to the 5mm bitumen seal to be applied
prior to the bedding sand and CBP surfacing, or the 7mm bitumen seal to be applied
as a de-bonding treatment prior to the placement of the jointed reinforced concrete
pavement.

The testing shall be at a frequency of one test for every 250 tonnes or 500 m 2 of
layer (whichever gives the highest number). The tests undertaken shall be;
a) Strength – to meet requirements in above,
b) Shrinkage Testing – to meet requirements above
c) Compacted Density Testing – to meet requirements in above,
Cover Material

If in the event traffic or equipment is to be allowed on the finished surface of the final
layer after the application of the curing membrane, a cover material shall be spread
over the curing membrane.

Material complying with the Specification for bedding sand shall be used. The cost
of this cover material is deemed to be included in the Contractor's rate for the cement
stabilised course.

Bedding Sand

The bedding sand shall comprise clean well graded sand from a single source
passing a 4.75 mm sieve and suited to concrete manufacture. The sand shall comply
with the following grading limits:

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 Sieve Size % Passing

1.25 cm 100

No 4 95-100

No 10 70-95

No 40 15-45

No 80 5-20

No 200 0-5

The bedding sand shall be free of deleterious soluble salts or other contaminants
likely to cause efflorescence. No deviation from these specifications shall be
permitted.

Single-sized, gap-graded sands or those containing an excessive amount of fines

shall not be used. The sand particles shall be sharp, not rounded. As a guide, but
subject to meeting the above grading, a sand suited to the manufacture of high-
quality concrete may be suitable.

The sand shall have uniform moisture content in the range 4-8%. Saturated sand
shall not be used.

The use of a cement-bound sand or grout in lieu of bedding sand shall not be
permitted.

The sand layer when compacted after the laying of the blocks shall be 20 mm thick,
minimum. Other than to cope with permissible tolerances in the base course surface,
sand shall not be used for filling local depressions in the surface of the base course.

Bedding sand shall be unloaded in small piles regularly spaced over the pavement
area, except where mechanised spreading and screeding is intended. Piles shall be
protected as necessary to avoid either saturation from rain or drying due to heat or
wind. As sand piles are spread, their bases shall be loosened to bring the sand to a
uniform condition.

The sand shall be maintained in as loose a condition as screeding operations will

reasonably permit until the paving units have been placed.

The bedding sand shall be screeded in a single uniform layer over the base course.
The screed shall be guided to the correct level by:

using an edge restraint or adjacent pavement, provided the line and level are
suited to the pavement profile; or

the provision of screeding rails consisting of hollow metal sections, timber or

stiff synthetic materials, set on the trimmed base course and having a rail depth
appropriate for the required loose or partially compacted thickness of the sand;
or

the use of tensioned string lines set above the base course (eg. when using
paving machines).

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 Screeding rails shall be typically set out 2-3 m apart for convenience. They shall be
moved by sliding longitudinally forward over the base course leaving about 500 mm
engaged in the sand.

At the time of screeding, the thickness of the sand must allow for the amount by
which it will be subsequently compacted. A small test area of paving units shall be
laid on 30 mm of loose sand which is then compacted with a plate compactor to give
an indication of the required loose thickness. Tests shall be repeated as necessary
for new deliveries of sand or changes in its moisture content.

Screed boards shall be rigid and span across the rails. The sand shall be distributed
evenly with a small surcharge maintained in front of the screed board across its full
length. Screeds shall be drawn longitudinally, using one or more passes.

Localised low areas or grooves left by screeding rails shall be filled and struck off
level behind the screed. Care should be exercised to maintain a full depth of sand
particularly adjacent to edge restraint and adjacent structures. Screeding of the sand
bedding shall not proceed too far in advance of laying and not more than one metre
beyond the planned end of paving-unit laying on that day.

When using a paving machine, the sand shall be discharged directly from a tipping
truck into the receiving bin or hopper of the paver and shall be spread, screeded and
partially compacted in a single pass.

The surface profiles of the screeded sand bedding prior to placing the paving units
shall match those for the completed pavement.
Concrete Blocks

The precast concrete blocks shall be 100mm x 200mm x 120mm deep and laid in a
herringbone pattern as indicated on the Drawings. The upper face shall have a 5 to
7 mm chamfer. Each vertical face shall incorporate 3mm spacer nibs – set at 1 per
100mm. Blocks shall have the following strength and abrasion resistance.

28 day strength 50 MPa minimum

28 day abrasion index 1.5 minimum (MA 20)

28 day flexural strength 4 MPa (AS/NZ 4456.5)

When laying the blocks, the Contractor shall schedule the delivery of pallets of paving
units and their placement close to the laying face, and pave on as wide a frontage
as site conditions will permit. Blocks ready for laying shall be laid on already paved
areas and not on the bedding sand.

Wherever possible paving shall commence adjacent to or against an edge restraint.

Paving shall not commence from opposite ends or adjacent sides and shall continue
forward on a single front. Where staged construction is unavoidable, an insitu, flush
edge restraint shall be provided to separate the two areas of pavement.

Care shall be exercised in positioning the first few rows. Paving units shall be placed
at the correct angle to the start line to achieve the final orientation of the laying
pattern.

The first few square meters shall be carefully placed and checked to ensure that
large gaps between paving units do not occur. The laying pattern and face shall be

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 established to permit laying such that it is never necessary to force a paving unit
between units already placed. To commence, only full units shall be used; cutting
and infilling at edges should follow after the laying face has advanced at least 2000
mm.

Blocks shall be placed to elevation 3mm to 5mm below or above the adjacent
concrete structures to allow rainwater to drain under gravity towards the drainage
system. The Contractor shall submit shop drawing to the Engineer for approval for
the proposed adjustments at each pavement interface.

In manual laying individual layers shall be rotated regularly so that the effect of
variations in joint widths is minimised. Blocks shall be placed with a gap not
exceeding 4 mm and not less 2 mm. Blocks shall not be tightly butted. An adequate
supply of blocks to the laying face shall be maintained.

Mechanised laying shall only be undertaken using equipment for transporting and
placing the clusters of paving units which has been approved by the Engineer.

Cutting paving units for infilling against edge restraints shall be deferred until
sufficient work has been completed to allow a reasonably continuous operation.
Hydraulic or mechanical guillotine block cutters or power saws shall be used.

The use of cut units less than 25 % of a full unit shall not be permitted. Where space
does not permit the use of a larger segment, either premixed or dry-packed concrete
shall be used.

As the laying proceeds, heavy duty vibrating-plate compactors shall be used over
the paving to compact the bedding sand and eliminate lipping between adjoining
units.

A minimum of two passes shall be made and compaction shall continue until a lipping
between units has been eliminated. The number of compactors required shall be
matched to the length along which the laying face is developed.

Compaction shall not proceed to within one metre of the laying face except on
completion of the pavement.

The testing shall be at a frequency of one test for every 250 tonnes or 500 m 2 of
layer (whichever gives the highest number). The tests undertaken shall be;
a) Strength – to meet requirements in above,
b) Abrasion – to meet requirements in above,

Jointing Sand

The joints between blocks shall be filled with joint-filling sand. The following grading
shall be used.

Sieve Size % Passing

No 10 95-100

No 20 70-95

No 30 60-90

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 No 50 30-60

No 100 15-30

No 200 5-10

Cement shall not be used in the sand.

The joint-filling sand shall be washed free of soluble salts or other contaminants, and
thoroughly dried before fully filling the joints.

Following completion of the bedding compaction, the joint between paving units shall
be progressively and completely filled with a jointing sand, without undue delay and
in any case prior to completion of construction activity on any day. The planning
operations for the paving shall include provision of suitable locations for stockpiles
of this material.

The blocks shall be as dry as possible when sand is spread.

The sand shall be broomed or spread over the surface with a small surcharge and
at a rate to keep up with the paving.

Sufficient passes of the plate compactor are required to vibrate the sand down into
the joints and to completely fill them.

Just prior to completion of the pavement area, further jointing sand shall be broomed
over the entire area and vibrated to fill the gaps formed by any intermediate
settlement of the sand.

Final compaction shall be by 10 passes of a pneumatic tyred roller having a gross

weight of not less than 10 tonnes. Other compaction methods may be adopted,
subject to the agreement of the Engineer and demonstration by the Contractor that
appropriate compaction has been achieved.

Until the joints have been filled, traffic over the pavement should be restricted to
equipment or vehicles involved in constructing the pavement.

An inspection of the pavement 6 weeks after completion shall be made and any
further joint gap shall be filled with broomed sand and further vibrated.

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 Bitumen

Material

Homogeneity

Bitumen shall be homogeneous and free from any inorganic matter other than
that naturally present in crude petroleum.

Foaming

Bitumen shall not foam when heated to a temperature of 185o C. The

formation of a thin layer of bubbles on the surface of the bitumen shall not be
regarded as foaming.

Properties

The properties of bitumen shall be as specified in the table below.

Property Unit Class 170 Class 320

Min Max Min Max

Viscosity at 60oC Pa.s 140 200 260 380

Viscosity at 135oC Pa.s 0.25 0.45 0.40 0.65

Penetration at 15oC (200 g, 60s) mm 8.0 - 6.0 -

Absolute Density at 15oC Kg/L 0.98 - 0.99 -

Flashpoint oC 250 - 250 -

Solubility in Toluene % 99.0 - 99.0 -

Viscosity of Rolling Thin Film % of - 300 - 300

Oven Residue at 60oC original

Testing

The Contractor shall submit for approval to the Engineer his proposed test methods
for the following properties:

Density

Solubility in toluene

Flashpoints

Penetration

Viscosity of rolling thin film oven residue

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 Viscosity

Compliance testing of bitumen shall be undertaken on a lot-by-lot basis.

Samples of compliance testing shall be randomly selected (random sampling) from

the delivery container(s).

A lot shall consist of a homogeneous quantity of bitumen of the same specification

requirements.

The Contractor is responsible for carrying out sufficient testing to ensure that the
material complies with the standards and requirements of this specification.

Information to be Provided by the Contractor

As part of the compliance testing results, the Contractor shall provide the following
information:-

(a) The name and location of the refinery producing the bitumen;

(b) The source (or sources) of the crude petroleum from which the bitumen has
been extracted;

(c) The process of manufacture including, where appropriate, the characteristics

and proportions of each components in any blended bitumen.

Maximum Reduction in Standards

Bitumen which has a dynamic viscosity at 60oC outside the limits given in the
Specification will not be accepted for a reduced level of service.

Bitumen Emulsion

Material

Bitumen Emulsion Grades

The grades of bitumen emulsion covered by this Specification are as follow:-

67% Bitumen Content Grades

(i) Cationic Rapid Set (RPS);

(ii) Cationic Aggregate Mixing (CAM);

Bitumen, Cutter Oil, Flux Oil

Bitumen, cutter oil and flux oil shall comply with the relevant Sections of the
Specification.

Emulsifying and Stabilising Agents

Emulsifying and stabilising agents shall have no known deleterious effect on the
properties of the bitumen.

Age and Storage

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 (a) Storage of bitumen emulsion shall be arranged to minimise contact with air by
using vertical tanks or keeping horizontal tanks full.

(b) Where the emulsion is stored in drum containers, the containers shall be
rotated end over end at least six times at intervals not exceeding 30 days.

(c) Drummed emulsion shall be used within 90 days of manufacture.

(d) Avoid mixing cationic with anionic emulsions.

Bitumen emulsion of one type shall not be place into a container in which the other
type has been held unless the container, pump, lines and spray bars have been
emptied and very thoroughly cleaned with an approved detergent compatible with
the emulsion type being removed.

Emulsion Properties

The properties of the bitumen emulsion with 67% bitumen content shall comply with
the requirements of the table below.

Property Emulsion Grade

CRS CAM

Particle Charge Positive Positive

Apparent Bitumen content (% by mass) 67 min 67 min.

Non-aqueous Volatiles Content (% by mass)

Sieve Residue(% by mass) 5 max. 5 min

Stone Coating Ability and Water Resistance 0.25 0.25

(% of aggregate surface area coated) max. max.

Aggregate Dry - 60 min.

Aggregate damp - 80 min.

Bitumen Emulsion Properties (67% Bitumen Content)

Testing

General

The Contractor shall submit to the Engineer for approval test methods for the
following properties

Residue from evaporation:-

(a) Solubility in toluene

(b) Dynamic viscosity

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 Sieve residue

Apparent bitumen content

Water content

Non-aqueous volatiles content

Consistency

Particle charge

Stability to mixing with Aggregate

Sedimentation

Stone coating ability and water resistance

Compliance testing of bitumen emulsion shall be undertaken on a lot-by-lot basis.

Samples for compliance testing shall be randomly selected (random sampling) from
the delivery container(s).

A lot shall consist of a homogeneous quantity of bitumen emulsion of the same

specification requirements.

The Contractor is responsible for carrying out sufficient testing to ensure that the
material complies with the standards and requirements of this specification.

The Contractor's testing program shall be such that the lot sizes are as nominated in
the Specification. As part of the compliance the testing results, the Contractor shall
provide the following information:-

(a) Information as required under the Specification

(b) The amount of cutter/flux, if any added and its source

(c) Details of the emulsifying and stabilising agents used.

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 Bitumen Cutter and Flux Oils

Material

Bitumen cutter oil, when mixed with bitumen, shall be capable of producing
homogeneous cutback bitumen which complies with the requirements of the
Specification

Medium Curing Cutback Bitumen.

Properties

Bitumen cutter and flux oils shall comply with the standards listed below

Cutter Oil Flux Oil

Property Units
Min Max Min Max
Aromatic % by
15 - 15 -
Content volume
Density at
kg/L 0.775 0.83 0.79 0.88
15oC

Distillation Range
Initial Boiling oC 140 - 175 230
Point

% of original volume recovered at:

150oC % - 10 - -
200oC % - 80 - 10
250oC % 80 - - -
300oC % - - 80 80
350oC % - - - -
Final Boiling oC - 270 - -
Point
Flashpoint oC 38 - 61.5 -
Water % by
- 0.1 - 0.1
Content volume
Viscosity at
MPa.s - 2 1.6 4.6
40oC
Miscibility
- no precipitation no precipitation no precipitation no precipitation
with Bitumen

Properties of Bitumen Cutter and Flux Oils

The Contractor shall submit to the Engineer for approval his proposed test methods
for the following properties:

viscosity

water content

density

flashpoint - cutter oil

flashpoint - flux oil

aromatic content

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 distillation range

miscibility with bitumen

Compliance testing of bitumen and/or flux oils shall be undertaken on a lot-by-lot

basis.

Samples for compliance testing shall be randomly selected (random sampling) from
the delivery container(s).

A lot shall consist of a homogeneous quantity of bitumen cutter and/or oil of the same
specification requirements.

The Contractor is responsible for carrying out sufficient testing to ensure that the
material complies with the standards and requirements of this specification.

The Contractor's testing program shall be such that the lot sizes and the testing
frequencies and number of tests are also as nominated in this Specification.

Medium Curing Cutback Bitumen

Material

Grades of Cutback Bitumen

The grade of medium curing cutback bitumen covered by this Specification is

AMCOO.

Bitumen and Bitumen Cutter Oil

Bitumen and Bitumen Cutter Oil shall comply with the requirements of this
Specification

Foaming

Cutback bitumen shall set firm during the distillation test.

Properties

Medium curing cutback bitumen shall comply with the requirements listed below.

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 Property AMCOO
Min Max

Dynamic Viscosity at 60oC (Pa.s) 0.008 0.016

Flashpoint (oC) 38 -

Distillation Test:-

(a) Distillate as % by volume of total distillate to

360oC (% volume)
- 15
- To 190oC
30 70
- To 225oC
55 90
- To 260oC
80 100
- To 316oC
40 -
(b) Residue from distillation to 360oC (% by
volume)

Tests on Residue from Distillation:-

(a) Dynamic Viscosity at 60oC (Pa.s) or 30 120

(b) Apparent Viscosity at 25oC, at a shear rate 15 80

of 0.01 (kPa.s)

(c) Master Soluble in Toluene (% by mass) 99 -

Application Temperature (oC) Ambient Ambient

Temperature of Supply

The temperature of cutback bitumen at the time of supply to the Site shall be such
as to ensure that the cutback bitumen may be applied to the Site within the temporary
range given above.

Testing

The Contractor shall submit to the Engineer for approval his proposed test methods
for the following properties:

Solubility in toluene

Dynamic viscosity

Apparent viscosity

Flashpoint

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 Distillation range

Compliance testing of medium curing cutback bitumen shall be undertaken on a lot-

by-lot basis.

Samples for compliance testing shall be randomly selected (random sampling) from
the delivery container(s).

A lot shall consist of homogeneous quantity of medium curing cutback bitumen of

the same specification requirements.

The Contractor's testing program shall be such that the lot sizes and the testing
frequencies are based on the daily supply to site with a minimum of two tests per lot
or as directed by the Engineer.

Pavement Prime

Material

Materials supplied by the Contractor shall comply with the requirements of the
relevant Sections of the Specification.

Compliance testing of materials supplied by the Contractor shall be carried out as

specified in the relevant Sections.

Surface Preparation

The surface to be prepared shall include the surface to be sprayed plus either an
area which is 250 mm beyond the surface to be sprayed, or one which extends to
the edge of the formation, whichever is the lesser.

The preparation work shall be carried out in a manner which will promote the
adhesion of the bitumen emulsion to the surface of the pavement.

All foreign and loose material, including lenses of pavement material, shall be
removed from the surface. The surface shall be swept with a road broom until the
larger particles in the surface of the pavement are slightly exposed without
dislodgment and/or excessive erosion of the surrounding finer material. A light
watering shall be carried out just prior to spraying.

Spraying

Spraying shall not take place during heavy or continuous rain or if heavy rain is
imminent.

The Contractor shall spray the bitumen emulsion in a uniform manner and in a way
which promotes adhesion of the bitumen emulsion to the pavement surface and to
the cover aggregate, and in accordance with the following clauses.

Method of Application

The Contractor shall submit to the Engineer for approval the proposed method by
which the bitumen emulsion is applied.

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 Spray Rate

The Contractor shall submit to the Engineer for approval the proposed spray rate(s)
prior to the commencement of spraying.

Other Pavement Types

The use of other pavement types shall not be permitted without the written
agreement of the Employer. In cases where other pavement types are adopted, such
works shall be executed in accordance with best international practice. Concrete
pavements shall comply with the requirements of Section 9 of this specification,
Concrete.

All design and details shall be submitted to the Engineer for approval at least 6 weeks
before commencement of the pavement works. The Contractor shall not commence
works without approval.

The Engineer may modify the Contractors proposal to meet international best
practice. The Contractor may not make any Claims for these changes.

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