National Oil Corporation Roads & Paving Specification

NATIONAL OIL CORPORATION
GENERAL ENGINEERING SPECIFICATION
GES Q.06
ROADS & PAVING
Rev Date Description Checked Approved

0 1999 Issued for Implementation DL
Compiled by Teknica (UK) Ltd

GENERAL ENGINEERING SPECIFICATION GES Q.06
ROADS & PAVING Page 2 of 24
Rev 0 1999
INDEX
SEC TITLE PAGE
1.0 SCOPE OF SPECIFICATION 4
1.1 Introduction 4
1.2 Other NOC Specifications 4
2.0 DEFINITIONS 4
2.1 Technical 4
2.2 Contractual 5
3.0 DESIGN 5
3.1 Codes and Standards 5

3.2 Units 8
3.3 General 8
3.4 Installation Description 9
3.5 Design Parameters 10
4.0 MATERIALS 13
4.1 Sub-base 13
4.2 Base Course 14
4.3 Crushed Aggregate Base Course 15
4.4 Bituminous Prime Coat 16
4.5 Bituminous Tack Coat 16
4.6 Asphaltic Concrete 16
4.7 Concrete Pavements 19
4.8 Joint Sealants in Concrete Pavements 19
4.9 Road Markings 19
4.10 Road Signs 20
5.0 CONSTRUCTION 20
5.1 General 20
5.2 Subgrade Preparation 20
5.3 Disposal of Surplus Material 21
5.4 Excavation 21
5.5 Trenches 21
5.6 Protection 21
5.7 Clean-Up 22
6.0 INSPECTION AND TESTING 22
6.1 Responsibility 22
6.2 Owner Access 22
6.3 Rejection 22
6.4 Notification 22
SEC TITLE PAGE

Rev 0 1999
7.0 DOCUMENTATION 22
7.1 Introduction 22
7.2 Schedule/Reports 23
7.3 Data and Calculations 23
7.4 Drawings 23
7.5 Final Records, Documents and Manuals 24
7.6 Warranty 24
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1.0 SCOPE OF SPECIFICATION
1.1 Introduction
1.1.1 This specification covers the minimum requirements for design, detailing, material supply and construction
of both offsite and onsite roads and paving.
1.1.2 Onsite roads and paving shall be of concrete construction except roads in tank farms which shall be gravel.
1.1.3 This specification applies to refineries, onshore oil and gas installations, and processing facilities.
1.1.4 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.
1.1.5 In the event of any conflict between this specification and the applicable codes and standards, the
Vendor/Contractor shall inform the Owner in writing and receive written clarification before proceeding
with the work.
1.1.6 This General Engineering Specification will form part of the Purchase Order/Contract.
1.2 Other NOC Specifications
The following NOC Specifications where applicable form an integral part of this specification and any
exceptions shall be approved in advance by the Owner:
GES A.01 Plant Layout and Spacing
GES C.03 Safety Procedures on Construction Sites
GES Q.01 Earthworks (inc. Site Preparation, Pits and Trenches)
GES Q.04 Concrete Structures
GES Q.07 Rainwater, Oily Water and Sanitary Sewer Systems
2.0 DEFINITIONS
2.1 Technical
The technical terms used in this specification are defined as follows:
Design Drawings
These are the conceptual design drawings that form part of the Purchase Order/Contract and may be
produced by the Owner, his appointed consultant or the Vendor/Contractor.
Detailed Engineering Drawings
These are detailed working drawings prepared by the Vendor/Contractor which must be submitted to the
Owner for approval and marked "Issued for Construction" prior to the commencement of construction.
During preparation of these drawings, the Vendor/Contractor is required to verify the accuracy of the
Design Drawings.
Substitutions
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The Vendor/Contractor shall submit in writing to the Owner, for approval, any proposals for substitutions
due to non-availability of materials or changes to the proposed design, prior to the commencement of work.
2.2 Contractual
The commercial terms used in this specification are defined as follows:
Owner
The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.
Vendor
The company supplying the equipment and material.
Contractor
The main contractor for a defined piece of work.
Sub-Contractor
A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.
Inspection Authority
The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.
Inspector
A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.
3.0 DESIGN
3.1 Codes and Standards
The following codes and standards, together with the references therein, shall be deemed to form part of
this specification. All recommendations shall apply, unless specifically modified herein.
3.1.1 American Standards
American Concrete Institute (ACI)
ACI 325.9R Recommendations for Construction of Concrete Pavements and Concrete Bases
American Association of State Highway and Transportation Officials (AASHTO)
AASHTO GDPS-4 Guide for Design of Pavement Structures
AASHTO GSH-7 Guide Specifications for Highway Construction
AASHTO M-43 Classification for sizes of aggregate for road and bridge construction
Rev 0 1999
AASHTO T-99 Standard method of test for moisture-density relations of soils using a 5.5 lb rammer
and a 12" drop
AASHTO T-134 Moisture-density relations of soil-cement mixtures
AASHTO T-135 Wetting and drying test of compacted soil-cement mixtures
AASHTO T-144 Cement content of soil-cement mixtures
AASHTO T-180 Standard method of test for moisture-density relations of soil using a 10 lb rammer
and an 18" drop
American Society for Testing and Materials (ASTM)
ASTM 04.03 Road and Paving Materials, Travelled Surface Characteristics
ASTM C-88 Test Method for soundness of aggregates by use of sodium sulphate or magnesium
sulphate
ASTM C-131 Test Method for resistance to degradation of small size coarse aggregate by abrasion
and impact in the Los Angeles Machine
ASTM D-422 Method for particle size analysis of soils
ASTM D-946 Specification for penetration-graded asphalt cement for use in pavement construction
ASTM D-1188 Test Method for bulk specific gravity and density of compacted bituminous mixtures
using paraffin-coated samples
ASTM D-1557 Test method for laboratory compaction characteristics of soil using modified effort
ASTM D-1883 Test Method for CBR (California Bearing Ratio) of laboratory compacted soils
ASTM D-2028 Specification for cut-back asphalt (rapid curing type)
ASTM D-2487 Classification of soils for engineering purposes (Unified Soil Classification System)
ASTM D-2726 Test Method for bulk specific gravity and density of non-absorptive compacted
bituminous mixtures
ASTM D-4318 Test Method for liquid limit, plastic limit and plasticity index of soils
Asphalt Institute (AI)
Manual Series Mix design Methods for Asphalt Concrete and other Hot Mix Types
No. 2 (MS-2)
Manual Series Soils Manual

No. 10 (MS-10)
Portland Cement Association
PCA Concrete Pavement Design Manual
3.1.2 British Standards
British Standards Institution (BS)

Rev 0 1999
BS 381C Specification for Colours for Identification and Special Purposes
BS 594:Part 1 Hot Rolled Asphalt for Roads and other Paved areas - Specification for Constituent
Materials and Asphalt Mixtures
BS 598: Part 102 Sampling and examination of Bituminous Mixtures for Roads and other Paved areas
-Analytical Test Methods
BS 873 Road Traffic Signs and Internally Illuminated Bollards
BS 1446 Specification for Mastic Asphalt (Natural Rock Asphalt Fine Aggregate) for Roads and Footways
BS 1447 Specification for Mastic Asphalt (Limestone Fine Aggregate) for Roads, Footways and Pavings in
Buildings
BS 1851 Specification for Titanium Dioxide Pigments for Paints
BS 3262: Part 1 Road Marking Materials: Specification for Constituent Materials and Mixtures
Concrete Society
Technical Report A guide to good practice for road edge details

No.10
Department of Transport (DOT)
Specification for Design Manual for roads and bridges Volume 7, Section 2 Part 3 - Pavement
highway works: Design
Transport and Road Research Laboratory
Report 87 Thickness Design of Concrete Roads
Report 512 The Design and Construction of Joints in Concrete Pavements
Note: Although superseded by the Design Manual above, the following may be considered approved by
this specification:
Road Research Road Note 29 - Pavement Design

Laboratory
British Cement Association (BCA)
BCA Guide 46.028 In-situ Concrete for Industrial Paving
3.1.3 Other Standards
The use of National Standards of other countries shall be subject to approval by the Owner. The
intermixing of National Standards from various countries is not acceptable. In the event of a conflict
occurring between codes, standards and this specification, the requirement leading to the safer design shall
be used as determined by the Owner.
3.1.4 Edition of Standards
Unless specified otherwise in the Purchase Order/Contract, the editions of the above codes and standards
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shall be those prevailing at the effective date of Purchase Order/Contract.
3.2 Units
SI derived metric units shall be used for all measurements, except nominal pipe sizes (NPS diameters)
which shall be in inches.
3.3 General
The Vendor/Contractor shall design, supply all materials and install roads and paving according to the
finalized, approved drawings and the codes and standards listed in this specification.
All necessary detail engineering drawings and calculations shall be prepared by the Vendor/Contractor for
approval by the Owner.
All topographical survey work required to prepare detail engineering drawings and to position the works
shall be undertaken by the Vendor/Contractor.
The plant site shall conform to current environmental requirements and shall be paved to the elevations and
contours indicated on the approved detail engineering drawings. Operating and building areas shall be
properly paved so that drainage will be carried away from these areas. All finished paving shall
incorporate natural drainage as far as possible, and provide a final drainage slope away from all
foundations and operating areas. The final slopes shall also direct the possible spillage of flammable
material away from open fires, fired heaters, boilers, buildings, etc. Special consideration shall be given to
directing contaminants which could result from a rupture, spill or washdown, to an approved contaminants
pond.
The Vendor/Contractor shall be responsible for all equipment and materials necessary for the execution of
the work including the supply of materials from public or private quarries or borrow pits including any
necessary reinstatement thereof.
The Vendor/Contractor shall provide any access roads and manoeuvre areas required for the execution of
the work including the construction of any ramps, accessways, etc, complete with all excavation and fill
compaction, etc.
The Vendor/Contractor shall undertake to remove and replace immediately all construction equipment and
tools which may have been damaged or broken during the course of the work.
The Vendor/Contractor shall be responsible for all upkeep and dust control. The method of dust control
shall be approved by the Owner.
The Vendor/Contractor shall be responsible for all shaping and profiling necessary together with any
templates or moulds.
Before starting the work, the Vendor/Contractor shall submit, for approval of the Owner, detailed
engineering drawings showing the material specifications and sequence of operations he intends to adopt,
and to ensure satisfactory surface conditions during execution taking full account of seasonal climatic
conditions.
The Vendor/Contractor shall be responsible for obtaining all information considered necessary for the
proper and workmanlike completion of the works.
A local datum level of 100.00 m shall be established for the process plot area in accordance with GES
A.01.
This local datum is usually taken as the high point of paving, and shall be related to the National Survey
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Datum for the area as a note on the detail engineering drawings.
For example: Local Datum Elevation 100.00 m = 4.60 m National Datum.
All levels shown on the drawings or mentioned in the documents shall be related to the temporary bench
mark established on site. The Vendor/Contractor shall establish all other levels and bench marks on site as
required and shall establish these bench marks to an accuracy of 3 mm.
Before any particular work is commenced the Vendor/Contractor shall submit for the Owner's approval, his
proposals for setting out the works to be constructed and for controlling to the dimensions and levels shown
on the drawings. The Vendor/Contractor shall give the Owner not less than twenty four hours notice in
writing of his intention to set out the works to enable the Owner at his discretion to make arrangements for
checking.
The Vendor/Contractor shall be responsible for the execution of all site and Laboratory tests for
establishing the characteristics of each material, mixture or the finished works. Offsite tests shall be carried
out in an independent Laboratory, approved by the Owner. Onsite tests shall be carried out as per the
requirements of the relevant ASTM.
The Vendor/Contractor shall be responsible for all other supply and services required in order to deliver the
works in a complete and workmanlike manner in accordance with the Purchase Order/Contract.
3.4 Installation Description
3.4.1 Layout
The overall setting out shall be in accordance with GES A.01. The road and paving layout detailed
engineering drawings shall be coordinated with the overall site plot plan produced in accordance with GES
A.01 and approved by the Owner.
The road layout shall provide access for fire-fighting vehicles to all sides of a process block and to bounded
storage areas within a tank farm.
A perimeter road inside the boundary fence shall be provided when specified by the Owner.
Provision shall be made for at least two (2) entrances to process units, utility plants and tank farms. Main
Administration buildings and carparks shall be accessible from a primary road.
Road junctions shall be not more that 30 m from each other, in areas where fire fighting access is required.
Turning radii at road junctions shall be designed to facilitate movement of the largest fire-fighting vehicle
in the event of an emergency or a minimum radius of 6 m.
A minimum distance of 6 m is required from the edge of equipment to the edge of the main access road.
A minimum distance of 2 m is required from the edge of equipment to the edge of minor accessways.
3.4.2 Road Categories
(a) Primary Roads
These carry general unrestricted traffic with direct access to the public highway from the site entrance.
Primary roads shall be 8 m wide with 1.5 m shoulder on each side. Primary roads shall normally be of
asphaltic concrete construction. The use of reinforced concrete roads is also permitted.
(b) Plant access roads
These carry normal maintenance vehicles and fire fighting equipment within the process and off site areas.
Plant access roads shall be 6 m wide. Plant access roads within refineries, GOSPs, or other process areas
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shall be of reinforced concrete construction. Kerbs and sidewalks (1 m wide) shall be provided on both
sides of roads within process areas except at locations where access to paved areas is required.
Offsite access roads shall be 6 m wide with 1 m shoulders on each side and shall normally be of asphaltic
concrete construction. Reinforced concrete roads may also be used.
Either asphaltic concrete or reinforced concrete roads shall be installed at camp sites. In either case kerbs
and 1 m wide sidewalks shall be provided on both sides of the road. Car parking at camp sites shall be
either in asphaltic concrete or reinforced concrete. Kerbs and sidewalks shall also be provided to carparks.
Roads in tank farms shall normally be gravel.
(c) Secondary or minor accessways.
These are restricted access roads within a process or offsite area and carry mobile maintenance vehicles and
cars. Minor accessways shall be a minimum of 4 m wide, with no shoulders provided. Within process areas
minor access roads shall be reinforced concrete type.
3.5 Design Parameters
3.5.1 General
Roads shall be reinforced concrete, asphaltic concrete, gravel or crushed stone as approved by the Owner.
All roads shall be designed for a wheel load of 12,000 lb (5,450 kg).
Prior to the commencement of design work, design speeds shall be stipulated by the Owner.
Raised kerbs are required at pedestrian pavements and where road drainage gulleys are installed.
Where the required base course thickness exceeds 150 mm the additional thickness may be either base or
sub-base material.
The compacted thickness of any single constructed course shall not exceed three times the largest aggregate
size in that course or a maximum of 150 mm for the base course, 75 mm for the levelling course, or 50 mm
for the surface course.
3.5.2 Geometry
(a) Clearance and Rails
Minimum horizontal clearance between a travelled way and any structure projecting above the shoulder at
grade shall be 0.9 m. The minimum vertical clearance shall be 4.88 m. Guard rails or guard posts shall be
installed at locations to be determined in the field.
(b) Road Crown
All hard surface paved roads and access ways shall have a minimum cross slope of 2%. Crushed rock
surfaced roads shall have a minimum cross slope of 4%. Road shoulders shall be sloped 4% away from the
road.
(c) Slope
Maximum longitudinal slope for roads and paved areas shall be 5%.
(d) Superelevation, horizontal and vertical sight distances

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Superelevations, horizontal sight distances and vertical sight distances shall be determined using the design
speed, as provided by the Owner, and the requirements of AASHTO.
3.5.3 Concrete Pavement
The design of concrete pavement for road or area surfacing shall be based on the design procedure
presented in the Portland Cement Association, "Concrete Pavement Design Manual" for concrete
pavements having protected corners.
Joints in concrete surfaces shall not become visible when the road has been opened to traffic.
Where concrete kerbs are provided for concrete roads they shall be subject to the Owner's approval.
3.5.4 Area Paving
Areas shall be paved under and around equipment such as towers, drums, exchangers, pumps, furnaces, etc.
and any location where spills may occur.
Paving shall consist of a reinforced concrete slab 100 mm thick on a base adequately prepared to support it.
Paving around equipment serviced by mobile equipment shall be 150 mm thick. The top surface shall be
an anti-skid type finish.
Area paving shall have a minimum slope of 1:120.
Paving shall be sloped so that any spills are drained away from the equipment. The edges of roads and
accessways shall be high points.
Furnaces fired with liquid fuels and/or having liquid in tubes shall have a 150 mm high concrete kerb
installed around them. Grading inside the toe wall shall slope toward one side to a catch basin for diverting
spills from under the furnace.
Where concrete surfaces abut foundations, equipment, pedestals, etc., a 13 mm wide expansion joint shall
be provided. A 20 mm expansion joint shall be provided for foundations supporting rotating equipment.
Expansion joints shall be provided in area pavement at spacing in accordance with BCA Guide 46.028.
Areas not paved shall be graded and surfaced with a 75 mm layer of 19 mm clean crushed stone on a
compacted gravel base with a minimum thickness of 100 mm.
A kerb shall be provided around paved areas where special hazards from spills may occur. The area within
the kerb shall be adequately drained to the appropriate sewer.
3.5.5 Crushed rock/gravel Pavement
Top course of gravel roads shall be constructed by spreading gravel on the base course, compacting by
rolling and blading to a crowned surface.
The design of crushed rock/gravel pavement for roads shall be based on AASHTO GDPS-4 with proper
substitution of crushed rock for asphalt.
Construction accessways shall conform to the following specifications. The sub-grade shall be 75 mm to
100 mm maximum size crushed gravel. A crown tapering off to grade at either side shall be added using 50
mm maximum size crushed gravel. The crown of the roadway, if specified, is to be finished by priming
with 2.76 l/m2 of MC-30 cut-back asphalt. The MC-30 coating shall be given time to soak into base course
and set. Coarse sand shall be applied at a rate of 13.5 kg/m2, then the surface shall be brushed lightly and
one pass made with an asphalt roller to press sand into the MC-30 coating. Where paving is specified, the
Rev 0 1999
MC-30 and sand treatment shall be deleted, MC-30 and paving with 50 mm of asphaltic concrete shall be
substituted.
3.5.6 Drainage
Where the water table is high, suitable drainage shall be provided for the subgrade. Consideration shall be
given to raising the grade of the road to eliminate this drainage requirement. Water shall be prevented from
rising to within 600 mm of the formation level. (See Section 5.2 for definition of formation level.)
Catchbasins shall be in accordance with GES Q.07.
Outlets shall be provided in the kerbs for draining the finished surface of roads and paving.
3.5.7 Pedestrian Walkways (Sidewalks)
Where concrete walks are specified, excavate sub-grade and place 75 mm of 20 mm crushed gravel and
cover with 100 mm of concrete complete with expansion joints, stippled surface and wire mesh reinforcing.
Where gravel walks are specified, place 100 mm of 20 mm, size compacted crushed gravel. These walks in
the plant area shall be 1.5 m width.
All sidewalks shall incorporate grating where ditches are crossed.
Walkways and pedestrian paths outside the main plant area at grade shall be a minimum of 1 m wide.
Surface finish shall be formed by drawing a stiff brush across the concrete before setting.
4.0 MATERIALS
4.1 Sub-base
Sub-base shall be in accordance with AASHTO-GSH-7 requirements.
The following types of sub-base shall be adopted as necessary.
4.1.1 Natural, Granular Material
The particle size distribution shall be subject to the following size limitations.
- maximum size = 100 mm

- passing through No. 200 sieve not more than 20%
4.1.2 Soil-Cement Stabilization
(a) The aggregates for the soil-cement stabilization shall be from a borrow pit approved by the Owner
and shall have the following characteristics:
- Particle size distribution based on percentages passing relevant sieves.
Table 1. Aggregate Sizes

Rev 0 1999
Sieve Size % Passing
75 mm (3") 100%
37.5 mm (1½") 90%
3
19.0 mm ( /4") 80%
3
9.5 mm ( /8") 70%
4.75 mm (No.4) 55%
2.0 mm (No.10) 40%
0.425 mm (No.40) 15%
0.18 mm (No.80) 5% to 7.5%
0.075 mm (No.200) Less than 5%
Atterberg limits on the material passing the No.40 sieve:
liquid limit < 40%

plasticity index < 12
(b) The minimum required compressive cube strength of the soil-cement mixture shall be 3.5 N/mm2
at 28 days. The minimum cement content shall be 5% by weight of soil.
(c) Before starting the works, the Vendor/Contractor shall carry out all the necessary preliminary tests
such as : Sieve Analysis, Atterberg limits, AASHTO T-180, T-134, T-135.
(d) The method for spreading of cement, wetting, mixing and compacting shall be specified by the
Vendor/Contractor and be subject to the Owners's approval.
(e) At the end of each working day and whenever the work has to be interrupted, an end stop shall be
placed in such a way as will allow the final part of the mixture to be satisfactorily compacted and
levelled. The compaction shall be carried out not later than 30 minutes after the addition of water
to the soil-cement mixture and shall be performed before the cement in the mixture starts setting.
4.2 Base Course
(a) The crushed stone shall consist of clean, tough, durable fragments and be free from an excess of
flat, elongated soft or disintegrated pieces.
The material shall be as per specification AASHTO M-43 with the following size distribution:
Table 2. Crushed Stone Sizes

Sieve Size % Passing
Standard Size No 3 Standard Size No 2

75 mm (3") - 100
63 mm (2½") 100 90-100
50 mm (2") 90-100 35-70
37.5 mm (1½") 35-70 0-15
25 mm (1") 0-15 -
19 mm (3/4") - 0-5
12.5 mm (½") 0-5 -
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The material must be angular and show uniform sizes in the different directions. When the material is made
by crushing gravel, the elements must show prevalent surfaces obtained by crushing, rather than rounded
surfaces, and their shape shall not be too elongated or flat.
(b) Fill shall be compacted at optimum moisture content, as determined by ASTM D-1557 Method D,
in layers not exceeding 6" (150 mm) compacted thickness or such other thickness as may be found
necessary to achieve the specified density.
Where soft areas develop during compaction the material in them shall be removed and replaced
by approved material.
Rolling shall be continued until the surface is properly compacted and closed. No sag or motion
shall appear when the road roller is travelling on the surface.
(c) When the rolling operation is over, the road bed shall have the shape and gradients shown on the
detail engineering drawings.
The allowable tolerance for unevenness shall not exceed 15 mm measured from a 3 m straight
edge.
(d) Before any section of the works is commenced and during its construction the Inspector may carry
out certain tests to determine the compaction in the fill and sub-grade. (This will also apply to
sub-base and crushed aggregate base course). All tests will be carried out as expeditiously as
possible after the Vendor/Contractor has given notice that the work is already for testing.
The Inspector may make use among others of the following tests:
(i) density/moisture tests;
(ii) density test;
(iii) CBR tests.
The laboratory compaction test shall be the modified AASHTO compaction test in accordance
with ASTM D-1557.
Laboratory CBR tests shall be performed in accordance with ASTM D-1883, and are conducted
on materials which have been obtained from site and remoulded to the density which will be
obtained during construction. Specimens shall be soaked for four days to allow the material to
reach saturation.
Field CBR tests shall be conducted in accordance with procedures given in Manual Series No 10
(MS-10) by the Asphalt Institute, current edition.
Sub-base shall be compacted to at least 95% of modified AASHTO maximum dry density, and
have a soaked laboratory CBR of not less than 30% at this density.
Sub-base shall be compacted in layers not exceeding 6" (15 cm) compacted thickness.
4.3 Crushed Aggregate Base Course
Crushed aggregate base course shall have a grading within the following limits:
Table 3 . Crushed aggregate Base Course

ASTM Sieve Percent Dry Weight Passing
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50 mm (2") 100
25 mm (1") 55-85
19 mm (¾") 50-80
4.75 mm (No.4) 30-60
0.425 mm (No.40) 10-25
0.075 mm (No.200) 3-10
The following requirements shall also apply for base course:
(i) The amount of material passing the No. 200 sieve shall not exceed half the fraction passing the
No. 40 sieve.
(ii) Material passing the No. 40 sieve shall have a liquid limit less than 25 and a plasticity index less
than 6.
(iii) Base course shall be compacted to at least 98% of modified AASHTO maximum dry density and
have a soaked laboratory CBR of not less than 80% at this density.
(iv) The coarse aggregate component shall be hard, durable and sound and when subjected to the
sodium sulphate weathering test shall give a weight loss not exceeding 12% after five cycles.
(v) Layers shall not be compacted less than 2½" (60 mm) compacted thickness and not more than 5"
(120 mm) compacted thickness.
4.4 Bituminous Prime Coat
4.4.1 Prime Coat Material
Bituminous prime coat shall consist of one of the following two cut-back bitumens:
Table 4. Prime Coat Material

Commercial Grade Specification Application Upper
Temperature Temperature
o o
F F
MC-30 (for very dense bases) ASTM 2027 68oF-122oF 140oF

MC-70 (for dense bases) ASTM 2027 86oF-150oF 175oF
4.4.2 Application of Bituminous Prime Coat
The material shall only be applied when the surface of the crushed aggregate base course is dry or just slightly
damp. The application rate shall be 1-1.5 kg/m2 (1.8-2.7 lb/yd2).
4.5 Bituminous Tack Coat
Bituminous tack coat where required shall be RC-250 complying with ASTM D-2028. It shall be applied to
the asphaltic concrete binder course at the rate of 0.2-0.6 kg/m2 (0.36-1.10 lb/yd2) within the temperature range
of 140°F-195°F.
4.6 Asphaltic Concrete

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4.6.1 Components of Asphaltic Concrete
Asphaltic concrete is to consist of carefully proportioned mixtures of coarse aggregate, fine aggregate and
mineral filler, all coated with bitumen in order to provide a dense, durable and stable pavement.
The various components of an asphaltic concrete are as follows:
(i) Coarse aggregate - material retained on the No. 8 ASTM sieve.

(ii) Fine aggregate - material between the No. 8 and No. 200 ASTM sieves.
(iii) Filler - material passing a No. 200 ASTM sieve.
(iv) Binder - petroleum bitumen.
4.6.2 Design of Mix
The asphaltic concrete mixes are to be designed so that the combined gradings of coarse aggregate, fine
aggregate and filler lie within the following grading envelopes:
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Table 5. Design Mix
Type of Mix 60 mm Thick 40 mm Thick
Binder Course Wearing Course
Material ASTM Sieve Size Total Percent by Weight Passing

Coarse Aggregate 25.0 mm (1") 100 -
19 mm (¾") 84-100 100
12.5 mm (½") 74-88 82-96

9.5 mm (_") 68-82 75-89
4.75 mm (No.4) 53-67 59-73

Fine Aggregate 2.36 mm (No.8) 40-54 46-60
1.18 mm (No.16) 30-44 34-48
600 µm (No.30) 20-34 24-38

300 µm (No.50) 13-25 15-27
150 µm (No.100) 9-17 8-18
Filler 75 µm (No.200) 3-6 3-6
Bitumen content % 4.5-7.0 5.0-7.5
The bitumen contents for the binder course and wearing course are expected to be in the range noted and are
expressed in percent by weight of the total mix.
The maximum size of aggregate shall not be more than half the thickness of the layer.
The grading shall not vary from the low side of one sieve to the high side of the adjacent sieve or vice versa
from coarse to fine.
4.6.3 Job Mix Tolerances
Once the proportions of the contents in the mixes have been fixed they shall be maintained within the
following limits:
Table 6. Job Mix Tolerance

Material Tolerance Plus or
Minus
Aggregate passing No. 4 sieve or larger 7%
Aggregate passing Nos. 8, 16, 30 and 50 ASTM 4%

sieves
Aggregate passing Nos. 100 and 200 ASTM sieves 2%

Bitumen 0.4%
The aggregate gradation may be adjusted within the limits of the table as directed by the Inspector.
4.6.4 Constituent Properties

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(i) Coarse Aggregate
When tested to ASTM C-131 Los Angeles abrasion test, the maximum loss shall be 40%.
When tested to ASTM C-88, the loss after five cycles shall not be greater than 9% with sodium
sulphate or 12% with magnesium sulphate.
(ii) Fine Aggregate
Liquid limit (LL) less than 25. Plasticity index (PI) less than 6.
(iii) Mineral Filler
If any filler is necessary, in addition to that naturally present in the graded material, it shall comply
with ASTM D-242.
(iv) Bituminous Material
Penetration grade 60-70

Specification ASTM D-946
Maximum mixing temperature 170°C
4.6.5 Marshall Design Criteria
The mixes shall have the following properties when representative specimens are compacted with 50 blows of
the Marshall hammer on each face:
Voids in mix 3%-5%
Minimum Marshall stability (kg) 320
Maximum Marshall flow 0.01 in (0.25 mm) 16
Minimum Marshall flow 0.01 in (0.25 mm) 8
The stability/flow ratio of the mix shall be sufficient to take normal heavy axle loads of road-going vehicles.
In order to prevent permanent deformation of the mix under high stress the Marshall Stability/Flow Ratio
should not be less than 1.2 times the maximum tyre pressure.
Tests on Marshall specimens shall be carried out in accordance with the Marshall Method procedures
contained in the Asphalt Institute's Manual Series No 2 (MS-2) current edition.
4.6.6 Mixing Time
Minimum mixing time for the asphaltic concrete mixture shall comply with the plant manufacturer's
recommendations.
4.6.7 Minimum Placing Temperature
The minimum temperature at which the asphaltic concrete shall be placed is 107°C (225°F).
4.6.8 Placing and Rolling of Mix
Placing shall begin on the centre line of crowned sections or on the high side of areas with a one-way slope.
The minimum laying width (except where edge lanes require less) shall be 3 m (10 ft).
Longitudinal joints in one layer shall offset that on the layer immediately below by at least 300 mm (1 ft).
Rev 0 1999
Transverse joints in one layer shall be offset by at least 600 mm (2 ft) from transverse joints in the previous
layer. Transverse joints in adjacent lanes shall be offset by a minimum of 3 m (10 ft).
Rolling shall be initiated with the drive wheel towards the paving. The sequence of rolling for the first paving
lane shall be to roll the lower edge initially and then the upper edge. The interior shall then be rolled from the
lower to upper sides.
The compacted paving shall have a density of not less than 98% of the laboratory Marshall density. Density of
cores shall be determined in accordance with ASTM D-2726 or ASTM D-1188.
4.7 Concrete Pavements
Concrete Pavements shall be designed to ACI 325.9R.
Concrete shall have a minimum compressive strength of 21 N/mm2 at 28 days.
All concrete constituents and associated materials such as cement, reinforcement, polythene sheeting under
concrete slabs, curing of concrete and joints in concrete, etc. shall be as per GES Q.04.
4.8 Joint sealants in concrete Pavements
Hot poured bitumen sealants are preferred to more expensive sealants.
4.9 Road Markings
4.9.1 General
Unless otherwise stated by the Owner, markings shall be white or yellow continuous or intermittent lines,
letters, figures, arrows or symbols laid to dimensions conforming with the requirements of the Purchase
Order/Contract.
4.9.2 Materials
Paint shall be suitable for applying by brush or mechanical means to concrete or bituminous pavement to give
a chemically stable film of uniform thickness and shall be either chlorinated rubber, one pack epoxy or alkyd
based.
White paint shall contain not less than 6% by mass of titanium dioxide as a pigment conforming to type A (A
natase) or type B (rutile) specified in BS 1851.
Yellow paint shall be standard colour BS 381C No. 355 and contain not less than 6% by mass of a suitable
yellow pigment.
The paint shall be supplied fresh and ready for use in sealed containers and stored in accordance with the
manufacturer's instructions.
Similar use shall have been demonstrated and found satisfactory.
Markings shall be reflectorised using ballotini, sprayed uniformly onto the wet paint at a rate of 400-500 g/m2.
Ballotini shall conform with the requirements of BS 3262: Part 1.
No order for paint shall be placed without prior written approval by the Owner.
4.9.3 Application
The paint shall be applied without the use of thinner or additives on a clean dry surface at a covering rate
Rev 0 1999
recommended by the manufacturer and agreed by the Owner.
Markings shall be free from ragged edges and shall be uniform and free from streaks.
Sample dressings shall have been made for approval purposes.
4.10 Road Signs
Road traffic signs shall be designed, supplied and installed by the Vendor/Contractor as specified in the
Purchase Order/Contract and shall comply with the requirements of BS 873.
5.0 CONSTRUCTION
5.1 General
Existing site conditions shall be inspected and assessed before commencement of the work on site.
All labour and plant, including all necessary excavating, transporting, lifting, haulage and transport equipment
to deal with every class of material shall be provided by the Vendor/Contractor.
All plant and machines shall be of approved type and shall be maintained at all times in good working order.
On completion of the work, all plant, equipment tools and all temporary works, surplus excavated materials
and debris shall be removed from the job site, to ensure that the site is left clean.
5.2 Subgrade Preparation
Preparation At and Below Formation Level
Definition of Pavement, Formation Level and Subgrade
(a) Pavement: Includes the asphaltic concrete wearing course and binder course, crushed
aggregate base course and sub-base, if used.
(b) Formation Level: Shall be the underside of sub-base or, where no sub-base is used, the underside of
crushed aggregate base course.
(c) Subgrade: Refers to the natural ground or filling below formation level.
Fill Under Road Formation Level
Satisfactory fill shall include materials classified by ASTM Test D-2487 as GW, GP, GM, GC, SW, SP or SM
and may be extended to SC, ML and CL subject to Owner's approval.
Subgrade Compaction Under Flexible Pavements
The subgrade shall be compacted to 95% minimum of the modified AASHTO maximum dry density. In
embankments fill shall be compacted to 95% minimum density throughout.
5.3 Disposal of Surplus Material
Excavated material which is approved for backfill shall be stock piled at a location on or adjacent to the
construction site and shall be used for backfill work as approved.
All surplus backfill material and unapproved materials shall be transported off the construction site to a
disposal area.
Rev 0 1999
Carting away, dumping and spreading at the disposal area of all surplus material from the site clearance and
general earthworks is the Vendor/Contractor's responsibility.
Location of disposal areas within the site boundary fence and location of tips outside the construction site shall
be subject to approval of the Owner.
5.4 Excavation
The excavations shall conform to the dimensions and elevations indicated on the detail engineering drawings.
All excavation shall be continued until solid ground is obtained, regardless of depth specified on any
construction drawing.
Work which is carried out in excess of that shown on detailed engineering drawings and/or specified in the
Purchase Order/Contract, must be reported and measured for verification, rectification and approval by the
Owner.
5.5 Trenches
Trenches shall be excavated to a minimum depth and width sufficient to allow satisfactory installation of the
pipe or other service. Backfill shall be as per GES Q.01.
5.6 Protection
5.6.1 Stability of Excavations
The stability of the sides of any excavations shall be maintained by the Vendor/Contractor until the works are
complete.
5.6.2 Area Drainage
The Vendor/Contractor shall be responsible to ensure that all excavated areas are kept reasonably free of water
at all times in order to prevent accumulation and creating a hazardous condition.
To keep the site "dry", area drainage shall be provided in accordance with detailed engineering drawings.
Provision shall be made to remove and safely dispose of any water which accumulates in any excavation or
trench.
The Vendor/Contractor shall be responsible to ensure that excavated areas are protected against flooding from
adjacent areas.
If filling work is undertaken during the season when rain may be anticipated then to avoid rain water
disturbances, all filling layers, even those not specified in construction drawings, shall have a slope of 1 to 2%
to allow free drainage. Adequate drainage systems for the fill shall be provided and maintained for the
duration of the works.
5.7 Clean-Up
As soon as the work is completed and approved, the area or roadway surfaces shall be restored promptly to the
equivalent of their original condition.
Where the Vendor/Contractor lays down a finished road for use during construction, the road shall be left in
good condition subject to approval by the Owner. Surplus soils shall be removed by the Vendor/Contractor to
an approved disposal area.
Rev 0 1999
6.0 INSPECTION AND TESTING
6.1 Responsibility
The Vendor/Contractor shall be fully responsible for the provision of adequate supervision to ensure that the
works are executed as indicated on the design and detailed engineering drawings, to the standards in this
specification and Purchase Order/Contract.
The Vendor/Contractor shall submit his inspection and testing programme for approval of the Owner, prior to
commencement of work. Before use, samples of all materials shall be subject to appropriate testing and no
material shall be used until it has been approved.
6.2 Owner Access
All design works and construction covered by this specification are subject to inspection by the Owner or his
Inspector. The Vendor/Contractor shall allow free access to the design office, fabrication yard and construction
site for inspection by the Owner's representative, however, such inspection shall not relieve the
Vendor/Contractor of his responsibility for the correct execution of the works.
6.3 Rejection
Roads and paving or parts thereof and material included therein, indicating irremedial or injurious effects,
improper construction, excessive repair or not in accordance with this specification, shall be subject to
rejection. They shall also be subject to rejection even if such conditions are discovered after previous
acceptance. All liability associated with rejection shall be borne by the Vendor/Contractor.
6.4 Notification
Adequate notification shall be given prior to the commencement of any stage of the work to allow inspection
by the Owner.
7.0 DOCUMENTATION
7.1 Introduction
7.1.1 This section covers the documentation required for the design, selection, construction, inspection and testing
for all equipment, components and services to be provided against this specification.
7.1.2 The detailed list of documents that are required is included in the Purchase Order/Contract. However, as a
minimum, the following listed documents will be provided by the Vendor/Contractor:
- list of key engineers and skilled operators with the resumés;

- details of similar work undertaken;
- list of proposed construction plant;
- methodology statement for the implementation of the work;
- survey and site investigation proposals;
- proposals for testing of materials.
7.1.3 The documents as listed may be considered as a minimum requirement; all details to confirm compliance with
the relevant specifications and to allow a full and continued appraisal to be made of the Vendor/Contractor's
proposals and interpretations of the awarded Purchase Order/Contract.
7.1.4 Any purchase or procurement undertaken by the Vendor/Contractor, which is prior to the relevant
documentation being submitted and reviewed by the Owner, is at the Vendor/Contractor's risk.
Rev 0 1999
7.1.5 On all documentation the Purchase Order/Contract number and project name shall be quoted.
7.1.6 All documentation shall be checked and signed by the checker before submission.
7.2 Schedule/Reports
7.2.1 The Vendor/Contractor shall submit with his tender a preliminary Quality Control Plan.
7.2.2 The Vendor/Contractor shall include with his tender documentation a statement of proposed sub-contractors, a
document submission schedule for all documents based on a review cycle of 3 weeks and outline programme
for procurement and construction activities.
7.2.3 The Vendor/Contractor shall incorporate any revisions agreed with the Owner during the enquiry review stage
and submit revised documentation for approval after the Purchase Order/Contract award.
7.2.4 Monthly reports shall be submitted by the Vendor/Contractor, detailing design, procurement, construction and
documentation activities, the format of which shall be agreed with the Owner.
7.3 Data and Calculations
7.3.1 Project specific instructions shall be issued to the Vendor/Contractor with the Purchase Order/Contract, which
describes the data and calculations to be submitted and the methods of submission.
7.3.2 All calculations shall be carried out in a clear and logical manner. Where conditions involve the use of
formulae or methods not specified in the Design Code, the source of these formulae or methods shall be clearly
referenced.
7.3.3 Computer calculations will only be acceptable if all the input is shown, together with calculated values of
intermediate terms and factors and options chosen, as well as final calculated dimensions, stress or other values
and the computer programme has been validated to the satisfaction of the Owner.
7.4 Drawings
7.4.1 The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner for
review and approval.
7.4.2 Layout drawings shall be to scale and show the relative location and main dimensions of all components,
including longitudinal profile and elevations.
7.4.3 As-built drawings may be the layout drawings marked-up with the actual as-built dimensions.
7.5 Final Records, Documents and Manuals
7.5.1 Two copies of the Data Dossier shall be supplied which shall be a record of the construction process. Where
stated in the Purchase Order/Contract it shall contain the following:
- layout drawings and bill of materials;

- the Quality Control Plan;
- material certificates;
- chemical analysis certificates;
- positive material identification certificates;
- Owner's Release Certificates.
7.5.2 The Vendor/Contractor shall produce as built documents, revised to indicate field changes.
Rev 0 1999
7.5.3 The Vendor/Contractor shall provide one set of mylar original drawings.
7.6 Warranty
7.6.1 The Vendor/Contractor shall warrant all materials and workmanship incorporated into the facilities against any
defect for a minimum of 12 months after Owner certified completion of the works, or for the period stipulated
int he Purchase Order/Contract.
7.6.2 Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated with
restoring it to the standard specified in the Purchase Order/Contract.

National Oil Corporation Roads & Paving Specification

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NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

ROADS & PAVING

Rev Date Description Checked Approved

Compiled by Teknica (UK) Ltd

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

3.1 Codes and Standards 5

6.0 INSPECTION AND TESTING 22

SEC TITLE PAGE

1.2 Other NOC Specifications

GES A.01 Plant Layout and Spacing

GES C.03 Safety Procedures on Construction Sites

GES Q.01 Earthworks (inc. Site Preparation, Pits and Trenches)

GES Q.04 Concrete Structures

GES Q.07 Rainwater, Oily Water and Sanitary Sewer Systems

The technical terms used in this specification are defined as follows:

Detailed Engineering Drawings

The commercial terms used in this specification are defined as follows:

The company supplying the equipment and material.

The main contractor for a defined piece of work.

3.1 Codes and Standards

3.1.1 American Standards

American Concrete Institute (ACI)

American Association of State Highway and Transportation Officials (AASHTO)

AASHTO GDPS-4 Guide for Design of Pavement Structures

AASHTO GSH-7 Guide Specifications for Highway Construction

AASHTO T-134 Moisture-density relations of soil-cement mixtures

AASHTO T-135 Wetting and drying test of compacted soil-cement mixtures

AASHTO T-144 Cement content of soil-cement mixtures

American Society for Testing and Materials (ASTM)

ASTM 04.03 Road and Paving Materials, Travelled Surface Characteristics

ASTM D-422 Method for particle size analysis of soils

ASTM D-2028 Specification for cut-back asphalt (rapid curing type)

Asphalt Institute (AI)

Manual Series Soils Manual

Portland Cement Association

PCA Concrete Pavement Design Manual

3.1.2 British Standards

British Standards Institution (BS)

BS 381C Specification for Colours for Identification and Special Purposes

BS 873 Road Traffic Signs and Internally Illuminated Bollards

BS 1851 Specification for Titanium Dioxide Pigments for Paints

Technical Report A guide to good practice for road edge details

Department of Transport (DOT)

Transport and Road Research Laboratory

Report 87 Thickness Design of Concrete Roads

Report 512 The Design and Construction of Joints in Concrete Pavements

Road Research Road Note 29 - Pavement Design

British Cement Association (BCA)

BCA Guide 46.028 In-situ Concrete for Industrial Paving

3.1.3 Other Standards

3.1.4 Edition of Standards

For example: Local Datum Elevation 100.00 m = 4.60 m National Datum.

3.4 Installation Description

3.4.2 Road Categories

(a) Primary Roads

(b) Plant access roads

Roads in tank farms shall normally be gravel.

(c) Secondary or minor accessways.

3.5 Design Parameters

(a) Clearance and Rails

(b) Road Crown